Metal-cutting machines are machines for processing workpieces in a precisely specified size by removing the allowance layer with the formation of chips.

For work, mainly abrasive or blade cutting tools are used. Machines also perform surface smoothing, rolling in rollers and other operations. Metalworking equipment allows the processing of metallic and non-metallic materials. For example, kapron, textolite, various types of plastics and wood, but special machines are intended for processing hard materials (ceramics or glass).

Classification of units by groups

The main division of the array of metal cutting machines occurs according to the technological method of processing, the method of moving mechanisms and the type of tool used.

There are 10 groups of machines:

• The first group is turning units. They make up about 30% of the machine park. Used for turning turning parts. The cutting movement for the group is the rotation of the workpiece.
• The second is drilling and aggregates. Their share is 20%; they are used for processing holes in various ways. The rotation of the tool and its feed with a stationary part are the main cutting movements. In boring machines, a table stroke with a part is added.
• The third - grinding, polishing, and lapping machines. They make up 20% of the total number of such equipment. Work with an abrasive tool. Polishing and finishing units use abrasive paste and powder, sanding belts and whetstones.
• Fourth - apparatus for physico-chemical processing and combined. This group includes, for example, the unit for.
• The fifth group includes gear-processing and thread-cutting devices. Make up 6% of the total park. Used for cutting different types of gears and. They perform roughing and finishing operations.
• Sixth - milling machines. They count 15% of the total number of equipment. The multi-blade milling cutters of various designs are a working tool.
• The seventh group - planing, lingering, mortising machines. They account for 4% of the machines. They have a straight working table movement. In mortising machines, the main movement is the reciprocating movement of the cutter. Broaching machines are used for machining holes and grooves using a multi-blade tool - broaches.
• Eighth - cutting machines. Serve for cutting workpieces such as a circle, corners, rods.
• Ninth group - different machines. This group includes machines for balancing, dressing and other operations.
• Tenth is reserve. Multipurpose machines like CNC equipment and machining centers allow implementing a number of machining methods. In accordance with the type of operations performed are included in one of the machine groups.

Type classification

Within each of the 10 groups, there is a division into 10 types in accordance with the following criteria:

• layout of base nodes;
• processing method and tool used;
• level of automation and other technological features.

For example, the group of grinding and polishing machines includes round and surface grinding machines, longitudinal grinding and grinding. In the group of planing and grooving machines - longitudinally planing single-rack, transverse-planing and grooving.

Within one type, there is a division into 10 sizes.

The classification of metal cutting machines according to the set of technological parameters is graphically presented in the table.

• manual control;
• semiautomatic devices, when the processing cycle is carried out automatically, and the operator changes the workpiece and turns on the machine;
• automatic machines, where many work cycles continuously occur automatically, without an operator, including tool replacement, loading and unloading of parts;
• cNC machines, they are made with the function of quickly changing the operating modes by adjustment.

Modern metal-cutting machines are manufactured with additional equipment, this speeds up the process of processing the material. Masters can increase the degree of automation in small-scale production, provided there is greater use of machines with numerical (cycle) program control (CNC). In their marking there is a letter F (C).

The digital designation behind the letter indicates the type of control system:

• digital display F1 - the system allows you to make a preliminary set of coordinates, the digital display displays in numerical terms the current position and movement of the movable node of the machine;
• rectangular or positional system Ф2;
• contour F3;
• universal Ф4 - combines contour and positional processing of a part.

Designation principle

Models of machine tools have an original designation, in the form of a combination of letters and numbers.

The following marking procedure has been established:

• the initial digit is the affiliation of the machine to the group;
• the next component shows its type;
• the third and fourth indicate a characteristic parameter (size of the workpiece, the size of the table).

Machine marking

The letter after the first or second digit indicates the modernization of the main parameters. Any letter that completes the marking except A, C, B, H, M, P and F shows the modification carried out with a change in the design of the nodes.

The letters A, C, P, B are the designation of the accuracy class. When the tool magazine appears at the machine tool, the letter M is added.

Modern types of metal cutting machines are different. For designation, F is used, but where there is a turret, it is present at the end of the marking R.

Such metal-cutting machines are very popular among craftsmen.

For example, the designation 2H135 indicates that it is a vertical-drilling machine of the second group, type 1, with modernization N. The maximum diameter of the drill being installed is 35 mm.

Video: General information about machine tools

Metal-cutting machines produced by domestic manufacturers are divided into several categories, which are characterized by the corresponding classification. You can determine which category this or that equipment belongs to by marking it, which says a lot to those who understand it. However, no matter what category the metal-cutting device belongs to, the essence of processing on it comes down to the fact that the cutting tool and the part make forming movements, namely they determine the configuration and dimensions of the finished product.

The most common types of machine tools: 1-6 - turning, 7-10 - drilling, 11-14 - milling, 15-17 - planing, 18-19 - long, 20-24 - grinding.

Types of metal cutting equipment

Metal-cutting machines, depending on the purpose, are divided into nine main groups. These include the following devices:

1. turning  - all varieties (in the markings are indicated by the number "1");
2. drilling and boring  - machines for drilling operations and boring (group "2");
3. grinding, polishing, lapping  - metal-cutting machines for lapping, grinding, grinding and polishing technological operations (group "3");
4. combined  - metal cutting devices for special purposes (group "4");
5. thread and gear processing  - machines for processing elements of threaded and gear joints (group "5");
6. milling  - machines for milling operations (group "6");
7. mortising, planing and lingering  - metal cutting machines of various modifications, respectively, for planing, grooving and broaching (group "7");
8. split  - equipment for cutting work, including saws (group "8");
9. various  - examples of such metal-cutting units - centerless-peeling, saw-cutting and others (group "9").

Groups and types of machine tools (click to enlarge)

In addition, metal cutting machines can be one of the following types:

• multi- and single-spindle, specialized (semi-automatic and automatic), multi-cutting, revolving, drilling-detachable, rotary, frontal and special;
• equipment for performing technological operations of boring and drilling: multi- and single-spindle, semiautomatic devices, vertical, horizontal and radial type, boring devices of coordinate, diamond and horizontal type, different drilling models;
• various types of grinding machines (flat, internal and circular grinding), peeling and polishing equipment, grinding and specialized units;
• types of metal-working machines designed for machining elements of gear and threaded joints: gear-cutting (including those designed for machining bevel gears), gear-cutting - for cylindrical gears, gear-milling, thread-cutting, thread-and gear-grinding, gear-finishing, testing, thread-milling, devices for processing the ends of teeth and elements of worm pairs;
• metal-cutting machines related to the milling group: cantilever (vertical, horizontal and wide-universal models) and non-cantilever (vertical devices, longitudinal, copy and engraving models);
• planing equipment and models for this purpose: longitudinal machines on which one or two racks are installed; horizontal and vertical broaching devices;
• cutting equipment: equipped with either a smooth metal disk, a cutter or saws of various designs (tape, disk, hacksaw); correct cutting types of metalworking machines;
• other types of machines for processing metal billets: dividing, used to control drills and grinding wheels, filing, balancing, right and centerless-peeling, sawing.

Vertical milling machine - one of the representatives of an extensive milling group

The classification of metal cutting machines is also carried out according to the following parameters:

• by weight and overall dimensions of the equipment: large, heavy and unique;
• by level of specialization: machines designed to process workpieces of the same size - special; for parts with different but identical sizes - specialized; universal devices on which it is possible to process parts of any size and shape;
• according to the degree of processing accuracy: increased - P, normal - N, high - B, especially high accuracy - A; also distinguish machines on which you can perform particularly precise processing - C, they are also called precision.

Machine marking

The classification of equipment intended for the processing of metal blanks suggests that, having seen its marking, any specialist will be able to immediately tell which metal cutting machine is in front of him. This marking contains alphanumeric characters that indicate individual characteristics of the device.

The first digit is the group to which the metal cutting machine belongs, the second is the type of device, its type, the third (and in some cases the fourth) is the main unit size.

After the numbers listed in the marking of the model, there may be letters that indicate whether the model of the metal cutting machine has special characteristics. These characteristics of the device may include its level of accuracy or an indication of a modification. Often in the designation of the machine the letter can be found after the first digit: this indicates that you have a modernized model, in the standard design of which any changes have been made.

As an example, the marking of the 6M13P machine can be decoded. The numbers in this designation indicate that we have a milling machine ("6") of the first type ("1"), which belongs to the 3rd standard size ("3") and allows you to perform processing with increased accuracy (letter "P" ) The letter "M", present in the labeling of this device, indicates that it has undergone modernization.

Automation levels

Types of lathes, as well as devices for any other purpose, which are used in conditions of mass and large-scale production, are called aggregate. They got this name due to the fact that they are completed from the same type of units (assemblies): bed, work heads, tables, spindle units and other mechanisms. Completely different principles are used to create machines that are necessary for small-scale and single production. The design of such devices, which are highly versatile, can be completely unique.

The classification of lathes (as well as equipment of any other categories) according to the level of automation implies their division into the following types:

1. manual models, all operations on which are carried out in manual mode;
2. semi-automatic, in which part of the technological operations (installation of the workpiece, start-up of the device, removal of the finished part) is performed in manual mode (all other operations related to auxiliary operations are automatic);
3. automatic, for the operation of which it is only necessary to set processing parameters, they perform all other operations independently, in accordance with a given program;
4. cNC cutting units (all processes on such machines are controlled by a special program that contains an encoded system of numerical values);
5. metal-cutting equipment belonging to the category of flexible automated modules.

The most prominent representatives of metal-cutting machines are CNC devices, the operation of which is controlled by a special computer program. Such a program, which the operator enters into the machine’s memory, determines almost all the unit’s operation parameters: spindle speed, processing speed, etc.

All types of metalworking machines equipped with a CNC system contain the following typical elements in their design.

• The operator’s console (or console), through which a computer program is stored in the machine’s memory that controls its operation. In addition, with the help of such a remote control, you can also perform manual control of all parameters of the unit.
• The controller is an important element of the CNC system, with the help of which not only control commands are generated that are transmitted to the operating elements of the equipment, and the correctness of their execution is controlled, but also all the necessary calculations are made. Depending on the complexity of the unit model, both a powerful compressor and a conventional microprocessor can be used as a controller to equip it.
• A screen or display acting as a control and control panel for the operator. Such an element allows real-time monitoring of the operation of a metal cutting machine, monitoring the processing process, and, if necessary, quickly changing parameters and settings.

The principle of operation of metalworking machines equipped with a CNC system is simple. First, a program is written that takes into account all the requirements for processing a particular workpiece, then the operator enters it into the machine controller using a special programmer. Commands embedded in such a program are sent to the working elements of the equipment, and after their execution the machine automatically turns off.

The use of metal-cutting machines equipped with numerical control allows you to perform processing with high accuracy and productivity, which is the reason for their active use to equip industrial enterprises that produce products in large batches. Due to their high level of automation, such units are perfectly integrated into large automated lines.

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TO  category:

Process design

Specialized Lathes

In addition to the high-performance machines discussed above, there are still quite a large number of varieties of machines for a specific turning, which we call “specialized” machines or even “special-purpose” machines.

Fig. 1. Specialized Sundstrand Lathe.

These machines are created by companies either for parts that, due to their shape or the required degree of accuracy, cannot be quickly and cost-effectively processed on the described types of machines, or to obtain particularly high productivity, or to achieve the concentration of a large number of operations on one machine.

In fig. 1 shows a specialized machine tool from Sundstrand Mch. Co for turning both flanges of the rear axle housing.

We have, in this case, a turning center machine with the following major modifications:
  a) the front and rear headstock of the machine are the same and are only center holders,
b) the rotation of the parts is carried out by the so-called “eentre-drive”, that is, the drive in the middle of the part,
  c) the machine is equipped with 4 calipers - two front and two rear,
  g) the change in the number of revolutions and feeds is carried out by interchangeable gears,
  e) idle and working movements of the calipers are automated.

Machine control is reduced to changing the part and putting the machine into operation.

For a clearer picture of this operation, we give a few more detailed data:

Sizes: diameter of flanges - 5 ", detail length - 53"
  Material: pressed and welded sheet steel.
  Stock: 1/16 to 5/32 ”.
  The greatest length of cutting: 1% ".
  Processing accuracy ± 0.002 ”per diameter and zt0.01” per length.
  Cutting speed: 100 feet per minute.
  Submission per revolution: front incisors 0.017 ”and rear - 0.023”.
  Productivity: 38 pcs. at one o'clock.

In fig. 3 shows the same machine on the turning of both ends of the axle shaft.

The drive is also implemented as in the previous treatment (due to its rigid structure it serves at the same time as a lunette).

Two front calipers produce longitudinal turning of all diameters, including the cone (a copying device).

Two rear calipers with wide shaped cutters give the final profile to both ends of the axle shaft.

The following data can be provided about this operation:
  Material: E. E. E. (C = 0.4-0.45%).
  Tolerance: 3/16 ”(per side).
  Processing Accuracy: +0.005 ”.
  Feed per revolution: 0.017 ”.
  Processing time 2 min. 25 sec (produces 21.5 units per hour with an efficiency of 85%).

The use of specialized multi-cutters can also be seen on the turning of the camshafts of a car engine

This processing is usually performed in 2 or 3 operations on special multi-cutters with 2 or 3 long calipers, most often located on one side, on which the required number of cutters is installed (up to 24 or more).

Fig. 3. Turning the axis on the SundstrMd machine.

Fig. 4. Lo-Su’ing machine - for turning cam rollers (specialized).

In order to avoid deflection of the roller from the pressure of the cutters, it is supported by one or more lunettes.

This treatment is often carried out in well-equipped mills on Seneca Falls Mach's specialized Bo-Swing machines. Co or, for large-scale production, on elongated Fay Automatic Lathe machines.

The latter machines, in view of the whole range of available devices, can also be considered specialized for the aforementioned processing.

Fig. 5. Cutting the necks of the cam roller on the Lo-Swing machine.

In Germany, Haiden-riech & Harbeck builds machines for this purpose.

In fig. 5 shows a nerve operation (trimming) of turning a camshaft on a Lo Swing machine.

The cam roller is supported during turning by two lunettes (from the side opposite to the incisors).

Therefore, before this operation, in addition to facing and centering, two necks of the shaft bearings must be machined, on which the rollers of the lunettes should rest.

Specialized multi-tooling for turning a camshaft differs from conventional multi-cutter tools with a longer bed, small height of centers, length, location and number of supports, arrangement of lunettes and, consequently, more power due to the large number of simultaneously working cutters.

One of the signs of the classification of machines is their degree of universality. It characterizes the variety of parts and operations for which the machine is suitable. The greater this diversity, the greater the technological capabilities of the machine.

From this point of view, all machines are divided into 4 groups:

General purpose machines  (widely-universal) - screw-cutting, vertical and horizontal milling, vertical and radial drilling, circular grinding, etc.

General purpose machines with increased productivity  - turning-revolving, turning automatic machines and semiautomatic devices, longitudinally and rotary-milling, centerless grinding, etc. (less versatile, have a smaller range of rotational speeds and feeds).
Machines of a specific purpose (specialized)  - gear cutting, gear milling, turning and copying, etc. (for operations of one name, a certain type of parts).

Special machines  - to perform only one operation in a single process. Special machines are divided into two types: ordinary special and aggregate.

The most widely used aggregation for machine tools drilling and boring groups.

In some cases, a special machine is created by upgrading any machine of another group, then they are called specialized. For example, it turns a lathe into a copy-milling machine (for machining the blade blade of a gas turbine engine), etc.

In ENIMS, a modern classification of machine tools has been developed. As the defining parameters of the classification, taken the detailed and target specialization, as well as the degree of automation of the equipment.

When describing the detailed specialization of systems, it is considered expedient to use the above terminology. According to the degree of automation, machines are divided into automatic, automated and non-automated.

In addition, the machines are further divided into single-purpose and multi-purpose (this term appeared together with CNC machines).

The following classification criteria is the accuracy of the machines:
   H - machines of normal accuracy - 16K20.
   P - machines of high accuracy, which is provided by improving the quality of manufacture and assembly of machines of normal accuracy - 16K40P, 53A30P.
   B - high precision machines (special design of individual units and high requirements for the manufacture, assembly and adjustment of the machine) - 3U10V.
   A - machines of especially high accuracy (higher requirements for manufacturing than in class B) - 16B16A, 3U10A.
   C - machines of particular precision - master machines (intended for the manufacture of parts for machines of classes A and B) - 2421С - coordinate-boring.
   The machines of classes B, A, C are operated in rooms with constant temperature and humidity.

Technological processes are being developed both in the design of new workshops and factories, and for existing workshops. In the first case, focus on the latest machine tools. In the second - develop TP taking into account the available equipment.
   When choosing equipment you should be guided by the following:

1. Technological appointment of machines - compliance with a specific operation.
2. Dimensions of the machine, its power and range of modes of its operation.
3. The accuracy of the machine and the required accuracy of manufacturing parts.
4. The volume of production of products - the performance of the machine.
5. The cost of equipment.

The range of machine quality indicators in GOST 4.93-83 is more fully described.

Machine tools depending on the type of treatment , divided into nine groups, and each group - into ten types (subgroups), characterizing the purpose of machines, their layout, degree of automation or the type of tool used. Group 4 is designed for EDM, ultrasonic and other machines.

The designation of the machine model consists of a combination of three or four numbers and letters. The first digit indicates the group number, the second number of the subgroup (machine type), and the last one or two digits are the most characteristic technological parameters of the machine.

For example:

1. 1E116 means single-spindle automatic turret with the largest diameter of the bar being machined 16 mm;
2. 2Н125 means vertical drilling machine with the largest nominal drilling diameter of 25 mm.

The letter after the first digit indicates the different versions and upgrades of the basic basic model of the machine. The letter at the end of the digital part means the modification of the base model, the accuracy class of the machine or its features.

The following indexing of machine tool models with program control is adopted:
   C - with cyclic control;
   F1 - with digital position indexing, as well as with a preliminary set of coordinates;
   F2 - with positional CNC system,
   FZ - with contouring CNC system; F4 - with a combined CNC system.
   For example:

1. 16D20P - high-precision turning lathe;
2. 6Р13К-1 - vertical milling console machine with a copier;
3. 1G340PTs - turning-turret machine with a horizontal head, high accuracy, with cyclic program control;
4. 2Р135Ф2 - vertical drilling machine with a revolving head, a cross table and with a positional system of numerical control;
5. 16K20FZ - lathe with contour numerical control system;
6. 2202VMF4 - a multi-purpose (drilling, milling and boring) horizontal machine of high precision with a tool magazine and with a combined CNC system (the letter M means that the machine has a tool shop).

Special and specialized machines are designated by the letter index (of one or two letters) assigned to each plant, with the model number of the machine. For example, mod. MSH-245 - semiautomatic reysoshiruyushchy of the increased accuracy of the Moscow factory of grinding machines