Specialization: Manufacturing Engineering Design and manufacturing of a turning table for fixing conical and torispherical heads, with a view to… [301811]

Faculty of Machine Building

Specialization: Manufacturing Engineering

Design and manufacturing of a [anonimizat] a [anonimizat]

([anonimizat], utilizate la vasele din industria berii)

[anonimizat],

Assoc. Prof. eng. [anonimizat].D. Adam Aurelian

2018

Inotec company presentation

Company history

S.C. Inotec S.R.L. was set up in the year 2002, having as associates : [anonimizat] a participation of 75% [anonimizat] a participation of 25% [anonimizat] 2811, [anonimizat]-Napoca, str. Al. Vlahuta, Lama F/78 [anonimizat], str. Calatis, nr. 23.

[anonimizat]. [anonimizat].

In 2007, following the acquisition of a [anonimizat]-Napoca, B-[anonimizat]. 16. We have also established that our main business activity is to become CAEN 2893, Manufacture of machinery for the processing of beverages and tobacco.

[anonimizat], beverage, pharmaceutical and body maintenance industry with a total of 67 employees and 24 external collaborators structured in three departments.

[anonimizat]. This department performs:

• Process diagrams;

• 3D engineering;

• isometric drawings for assembly;

• lists of materials for mechanical fitting;

• Workshop production department that performs a [anonimizat]:

• Pre-assembled equipment for the beverage industry ([anonimizat]);

• modules (pasteurizers, coolers, heaters, [anonimizat]);

• Wide range of tanks (fermentation, storage, dosing tanks).

[anonimizat] a echipamentelor, punerea în funcțiune a instalațiilor, și instruirea operatorilor.

At the end of 2016 we decided to acquire a production area with a [anonimizat] I [anonimizat], no. 19, who is now in the process of planning to move production to this new headquarters. [www1]

[anonimizat]. [anonimizat], [anonimizat].

The activity of the group is structured in three domain of competence.

Industrial Engineering Department provides a [anonimizat].

Design of Process diagrams (P&ID’s) based on today’s technology

3D Engineering of complete plants

Provide Montage and Installation isometric drawings

Generate material extracts for mechanical erection

Production Department supply an extensive range of process modules pre-assembled in our factory and ready to operate. The systems are available as independent skids easy to integrate in new or existing processes.

Pre-assembled equipment for fluid handling – Valve blocks, Swing bend panels

Skid mounted equipment – pasteurizers, coolers, heaters, carbonators, aeration units

Pre-assembled plants – CIP Plants, Yeast Propagation and Storage

Various range of tanks – Yeast, CIP, Water, BBTs

Montage and Installation Department provides mechanical and electrical works to install and commission beverage and diary plants.

Mechanical Installation of Equipment and Pipework

Electrical Installation of Control panels, Cabling and Sensors

Start-up and Commissioning of the plants

Assistance and Training of the Beneficiary Personnel

Inotec S.R.L. [1]

Process technology

Delivery purpose, capabilities and services

The company

Head office: Cluj-Napoca, România

Facilities

Offices- 600 mp

Production Workshop – 3000 mp

Activities:

Process engineering for: beer, dairy, soft drinks, food industry, commerce-detergents industry; Prefabrication of modular process equipment;

Plant assembly and installation;

Turnover: 8 mil. EURO (2016)

Employees:

4 employees – design engineers

3 employees – production engineers

2 employees – project managers

3 employees – quality management department

6 employees – site engineers

45 own employees – specialized workers

36 external employees – specialized workers

2 employees – purchasing department

12 employees – administrative staff

Process Engineering provides a wide range of products and services to develop and create fully integrated process solutions:

Process diagrams design (P & ID's) based on current technology

Engineering of prefabricated modules

3D engineering for factories

Providing isometric sketches for installation and assembly

Generate lists of materials for mechanical assembly

Engineered prefabricated modules

Process Modules;

Module heating and cooling product;

Modules for the preparation of process gases;

Valve blocks for product distribution;

Switchgear panels

Factory 3D engineering offers an accurate investment perspective.

Building

Tanks, pumps and equipment

Bridges / pipe supports

Product piping

Utility pipes

Switchgear panels

Installation and installation drawings

Detailed mounting drawings provide support for an easy and accurate installation.

Side views

Isometric views

Section views

Bridges / Support pipes

Drawings for each equipment

Lists of installation materials

Engineering software allows generating accurate inventory of materials:

List of tanks and specifications

Components (pumps, HEX, valves and instruments / sensors)

Installation materials (pipes, elbows, T-taps, reducers, flanges, nozzles / nozzles, pipe clamps, etc.)

Materials for pipe bridges and supports

List of materials for each route

List of route isolation materials

Our production workshop is fully equipped to manufacture a wide range of modular equipment ready to be put into operation.

Prefabrication of process modules

Modules for handling fluids

Valve blocks

Switchgear panels

Fence installation

Orbital welding

Hygienic concept

Pasteurizers for soft drinks

Carbonators and blenders

Heaters and produc coolers

Pre-assembled equipment / units

CIP module (Clean In Place)

Water distribution module

Modules for filtering

Installation and assembly

Our specialized plumber team has the ability to provide high quality services in mechanical and electrical installations for the food industry, refreshments, dairy, chemicals, detergents and cosmetics.

Our locksmith and welders are certified by TÜV for the execution of high quality works using technological methods designed to ensure fast and reliable installation.

Process installations

25 mm ≤ DN ≤ 500 mm, -50°C ≤ T ≤ +440°C, Pmax ≤ 40 bar

Utility routes

32 mm ≤ DN ≤ 800 mm, Tmax ≤ +440°C, Pmax ≤ 40 bar

Competences

Beer factories

Refreshment factories

Dairy products

Factory detergents

Cosmetic products

Lines of packaging

Factory relocation

References – Brewers

References – Detergent and cosmetic factory

Actual study

In a research realized by a group of researchers from Department of Mechanical Engineering, Politecnico di Milan, Milan, Italy and Department of Chemistry, Materials, and Chemical Engineering "Giulio Natta", Politecnico di Milano, Milan, Italy about importance of roughness from the stainless steels surface in food and beverage industry was presented in the article entitled “Laser micro-polishing of stainless steel for antibacterial surface applications” , published in The Second CIRP Conference on Biomanufacturing in 2015. Within the made research, they used stainless steel 304 alloy sheets. The sheets were cold rolled to 0.5 mm thickness. The surface average roughness Sa was 85.3±2.8 nm, instead the surface average waviness Sa was 56.4±5.6 nm. The material nominal chemical composition is summarized in Fig 2.1.

Fig 2.1 The material nominal chemical composition [CHI16]

Before LMP (laser micro-polising), they cleaned the specimens in ultrasonic bath cleaning with deionized water (10 minutes), ethanol (10 minutes) and deionized water (10 minutes). Then they dry the samples in nitrogen. [CHI16]

A Q-switched fibre laser (YLP-1/100/50/50 from IPG Photonics, Oxford, MA, USA) in fundamental wavelength (λ=1064 nm) they used coupled to a scanner head (TSH 8310

by Sunny Technology, Beijing, China). They equipped the scanner head with an f-theta lens (SL-1064-70-100 from Wavelength Opto-Electronic, Ronar-Smith, Singapore), with focal length of 100 mm; so the calculated beam diameter in focal point was 39 μm. The researchers positioned the workpiece in Zaxis with L490MZ/M motorized lab jack from Thorlabs, inside a gas chamber. The main specifications of the employed laser system are summarized in Fig 2.2. [CHI16]

Fig. 2.2 The main specifications of the employed laser system [CHI16]

The chamber, they designed and built in laboratory, was allows working under inert atmosphere and avoiding in this way the material oxidation. They focused on the design of chamber particularly on dimensions, considering first of all the limitations due to the necessity to integrate the chamber in the employed laser system. Fig. 2.3reports the assembled laser system. [CHI16]

Fig. 2.3 The assembled laser system. [CHI16]

The experiment what they made was conducted to define the feasibility of LMP. In the explorative work laser beam was focused 2 mm above the surface to generate a larger spot and to reduce energy intensity on the material surface; in this way material removal was avoided and processing conditions yielded melting of a superficial layer. The calculated beam diameter ds on the workpiece was 124 μm. Laser pulse energy (E) was maintained between 0.10 and 0.64 mJ. LMP (laser micro-polishing) surface structuring consists of scanning the laser beam on a two dimensional plane to overlap laser pulses on the material. Scanning speed (v) was changed from 25 to 6000 mm/s . The overlapping of the successive scan lines depends on the pitch (p) which was set as 10 μm in all experiments. It was also possible for they to increase the number of passes (N) on the scanned area, with different angles to eliminate directionality on the surface. Within this study, single passes (N=1) were done at 0°, which was defined as perpendicular to the grinding traces on the material. In multiple passes, the scan angle followed 0° and 90° (N=2) or 0°, 90°, 45° and 135° (N=4). A schematic representation of scanning strategy can be seen in Fig. 2.4. [CHI16]

Fig. 2.4 Scheme of the employed scan angle strategies with single pass (A), double passes (B) and four passes (C). [CHI16]

The experiments what the researchers made were conducted under atmospheric conditions (without shielding gas), under argon and under nitrogen; however, with argon and nitrogen, the gas pressure was set constant at 0.3 bar and measured through a pressure gauge placed inside the gas chamber. They apply different processing conditions in 3×3 mm2 squares. The Fig. 2.5 summarizes the defined experimental plan, classifying fixed, varied parameters and measured variables. [CHI16]

Fig. 2.5 The defined experimental plan, classifying fixed, varied parameters and measured variables. [CHI16]

In order to assess the effect of laser process parameters and define the feasibility of LMP, results were analyzed categorically through visible inspection under optical micorscope, with polished (P) and unpolished (U) states as output. Fig. 2.6 reports optical microscopy images showing example surfaces belonging to the defined categories. As can be observed in Fig. 2.6.a polished surface is smooth, free of surface macro-defects, and surface irregularities from the previous manufacturing processes are absent. On the other hand, an unpolished surface corresponds to surfaces with excessive melting, often accompanies by oxidation and roughnening, as depicted in Fig. 2.6.b. For a preliminary characterization, on chosen surfaces Sar, Szr, Saw and Szw were measured. [CHI16]

Fig. 2.6 Optical microscopy images of a polished (a: N2 E 0.19 mJ v 400 mm/s

N 2) and an unpolished (b: None E 0.19 mJ v 200 mm/s N 1) surface. [CHI16]

As a conclusion of this experiment LMP of 304 stainless steel the researchers investigated using different process parameters such as laser pulse energy, scanning speed, shielding gas flow and scanning strategy. They successfully demonstrated that the perfomance of LMP treatment in improvement of the surface finishing, also for an already good initial surface roughness. As was observed with focus variation microscopy, this is due to the filling of surface asperities and grain boundaries with the molten material surface during remelting process. In this study the surfaces were first classified in polished and unpolished, through a simple visual analysis, allowing the definition of a process feasibility map. Polished surfaces can be obtained, in particular, working under both Ar and N2 and thus avoiding the material oxidation. In the preliminary analysis under Ar, roughness and waviness could be decreased by 50% and 29% respectively. With the optimisation of the inert gas and process parameters the decrease in roughness is expected to further increase. A part the optimisation of the process, future works will be dedicated to evaluate the functionality of laser micro-polished surfaces in the context of antibacterial applications. [CHI16]

Fixture devices

The fixtures devices are the economical devices to produce a component in a simple way in mass. Fixtures devices are practical and are used to serve as one of the most important facility of mass production system. These are special work holding and tool guiding device. Quality of performance of a process is largery influenced by the quality of jigs and fixtures used for this purpose. What makes a fixture unique is that each one is built to fit a particular part or shape. The main purpose of a fixture is to locate and in the cases hold a work piece during an operation. A jig differs from a fixture in the sense that if guides the tool to its correct position or towards its correct movement during and operation in addition to locating and supporting the work piece. [www2]

Fig. 2.7 Jigs. [www2]

An example of jig is when a key is duplicated; the original key is used as base for the path reader which guides the movement of tool to make its duplicate key. The path reader of a CNC here works as a jig and the original is called template. Sometimes the template and jig both are the name of same part of a manufacturing system. [www2]

Fig. 2.8 Schematic jig [www3]

A fixture is a device used to locate, clamp and support a work piece during machining, assembly or inspection. The most important criteria’s for fixturing are work piece stability, position accuracy and work piece deformation. A good fixture design is one that minimizes work piece geometric error. Work piece location principles are defined in terms of 3-2-1 fixturing which is widely used work piece location method for prismatic parts. Force analysis is concerned with checking whether the forces applied by the fixture and clampling are sufficient to maintain static equilibrium. [www2]

Fig. 2.9 Fixtures [www2]

A fixture is a work holding device that holds, supports and locates the workpiece for a specific operation but does not guide the cutting tool. It provides only a reference surface or a device. What makes a fixture unique is that each one is built to fit a particular part or shape. The main purpose of a fixture is to locate and in some cases hold a workpiece during either a machining operation or some other industrial process. A jig differs from a fixture in that a it guides the tool to its correct position in addition to locating and supporting the workpiece. Examples: Vises, chucks. [www3]

Fixtures must correctly locate a work piece in a given orientation with respect to a cutting tool or measuring device, or with respect to another component, as for instance in assembly or welding. Such location must be invariant in the sense that the devices must clamp and secure the work piece in that location for the particular processing operation. There are many standard works holding devices such as jaw chucks, machine vises, drill chucks, collets, etc. which are widely used in workshops and are usually kept in stock for general applications. Fixtures are normally designed for a definite operation to process a specific work piece and are designed and manufactured individually. [www2]

Fig. 2.10 Schematic fixture [www3]

Purpose and advantages of Jigs and Fixtures.

Following the purpose and advantages of jigs and fixtures:

It reduces or sometimes eliminates the efforts of making, measuring and setting of work piece on a machine and maintains the accuracy of performance.

The work piece and tool are relatively located at their exact positions before the operation automatically within negligible time. So it reduces product cycle time.

Variability of dimensions in mass production is very low so manufacturing processes supported by use jigs and fixtures maintain a consistent quality.

Due to low variability in dimension assembly operation becomes easy, low rejection due to les defective production is observed.

It reduces the production cycle time so increases production capacity. Simultaneously working by more thane one tool on the same work piece is possible.

The operationg conditions like speed, feed rate and depth of cut can be set to higher values due to rigidity of clamping of work piece by jigs and fixtures.

Operators working become comfortable as his efforts in setting the work piece cand be eliminated.

Semi-skilled operators can be assigned the work so it saves the cost of manpower also.

There is no need to examine the quality of produce provided that quality of employed jigs and fixtures is ensured. [www2]

Importance of Fixtures in Manufacturing

The use of fixtures has two fold benefits. It eliminates individual markings positioning and frequent checking before machining operation starts, thereby resulting in considerable saving in set-up time. In addition, the usage of work holding devices saves operator labor through simplifying locating and clamping tasks and makes possible the replacement of skilled work force with semiskilled labor, hence effecting substantial saving in labor cost which also translates into enhanced production rate, Furthermore, the use of well-structured fixtures with higher locating and clamping rigidity would allow for increase in cutting speeds and feeds, thereby reducing tm, hence improving production rate. Besides improving the productivity in terms of the rate of production, there are also other benefits accured through the use of fixtures, they are: It increases machining accuracy because of precise location with fixtures. [www2]

Following the purpose the fixtures devices are intended to provide them with a well-defined position relative to the directions of some movements.

The classification of fixtures devices in terms that how they action is:

-Fixing devices with hydraulic action;

-Fixing devices with pneumatic action;

-Fixing devices with manual action;

Polishing

Polishing and buffing are finishing processes for smoothing a workpiece's surface using an abrasive and a work wheel or a leather strop. Technically polishing refers to processes that use an abrasive that is glued to the work wheel, while buffing uses a loose abrasive applied to the work wheel. Polishing is a more aggressive process while buffing is less harsh, which leads to a smoother, brighter finish. A common misconception is that a polished surface has a mirror bright finish, however most mirror bright finishes are actually buffed. [www4]

Polishing is often used to enhance the appearance of an item, prevent contamination of instruments, remove oxidation, create a reflective surface, or prevent corrosion in pipes. In metallography and metallurgy, polishing is used to create a flat, defect-free surface for examination of a metal's microstructure under a microscope. Silicon-based polishing pads or a diamond solution can be used in the polishing process. Polishing stainless steel can also increase the sanitary benefits of it. [www4]

The removal of oxidization (tarnish) from metal objects is accomplished using a metal polish or tarnish remover; this is also called polishing. To prevent further unwanted oxidization, polished metal surfaces may be coated with wax, oil, or lacquer. This is of particular concern for copper alloy products such as brass and bronze. [www4]

Fig 2.11 An unpolished tank head (left) and a polished tank head (right). [www5]

Types of polishing machines with turning table

Polishers machines are used to impart a fine (low Ra) surface finish on the exterior of a part. To improve surface finish, they use abrasive grain slurries or compounds on:

buffs

bobs

cloth naps

laps

very fine grit non-wovens

coated abrasives [www6]

Many types of polishing machines are available. Choices include:

disc finishing machines

centerless finishing machines

buffers

cylindrical polishers

honing machines

lapping machines

orbital devices

polishing lathes

super-finishing equipment

vibratory or oscillatory machines

specialty devices [www6]

Disc finishers, buffers, and centerless finishers are common types of polishers and buffing machines. Disc finishing polishing machines and buffing machines are abrasive grinders or grinding wheel face-grinders. Buffers and buffing machines are used to improve a surface’s brightness or finish. Buffers drive either non-woven abrasive pads or buffing pads that are loaded with buffing or polishing compounds. Centerless finishing polishers and buffing machines are used for grinding or finishing. Applications for centerless polishers and buffing machines include rolls, rollers, connecting rods, valve systems, and other precision symmetric shapes. Centerless machines are used in high-volume production applications, which include throughfeed and plunge grinding. [www6]

Cylindrical, honing, and lapping polishers and buffing machines are also available. Cylindrical or outer diameter (OD) polishers and buffing machines are used in grinding and polishing in small spaces, such as shafts, rolls, cams and valve systems. Cylindrical polishing machines and buffing machines may be used in additional applications. Honing machines use bonded, abrasive stones or super-abrasive sticks mounted within a fixture. The fixture rotates and reciprocates when it’s applied to the surface. Honing equipment corrects the alignment of holes to produce the correct surface for the application. Lapping polishers and buffing machines generate flat surfaces with fine finishes. They use a loose abrasive in a carrier fluid where parts are processed between large lap plates. Lapping removes much less material than grinding and polishing. [www6]

Additional types of polishers and buffing machines include polishing lathes, super-finishers, and vibratory or oscillatory equipment. Orbital polishers and buffing machines use an orbital motion during finishing or grinding. Polishing lathes are specialized polishers and buffing machines that produce smooth or fine surface finishes. They have two tapered shafts that provide tool holding chucks. Super-finishing polishers and buffing machines produce surfaces with very low roughness. Vibratory or oscillatory polishers and buffing machines use a vibrating motion during finishing. Specialty polishers and buffing machines are also available. Applications include scarifiers, power files, scrapers, thermal stripping, and wafer thinning. [www6]

JT-2 Tank dished head polish buffing machine

Fig 2.12 JT-2 Tank dished head polish buffing machine. [www7]

Application:

This model is suitable for all kinds of standard heat polishing, conical head polishing, spherical head polishing, thorispherical head polishing, pressure head polishing, deformed head polishing, stainless steel elliptical head polishing, pressure vessel head polishing and stainless steel sealing head inside & outside polishing. [www7]

The head polishing machine is extensive apply for the polishing of work piece in the range of medical, chemical, environmental purification, food and beverage, water filtration etc.

Product Features:

The machine makes surface friction through the contact of polishing wheel and the work piece then to polish the head surface inside and outside, and grind weld surface, and improve the surface smoothness of the work piece. [www7]

The Beam walks from the scheduled direction. The walking speed of beam from up to down and from the left to right both according to the actual data in the panel, according to the grinding head floating technology, the grinding head close to the work piece’s surface to grind uniformly when the machine is polishing, it is suitable for a small amount of work piece polishing. [www7]

Table 2.1 Specifications for JT-2 Jotun Head Dish Polisher [www7]

3000mm Diameter Dish Head Polishing Machine

Application:

This model is suitable for all kinds of dished ends polishing, conical head polishing, spherical head polishing, torispherical head polishing, pressure vessel head polishing, deformed head polishing, stainless steel elliptical head polishing, pressure vessel head polishing and stainless steel sealing head inside & outside polishing. The head polishing machine is extensive apply for the polishing of work piece in the range of medical, chemical, environmental purification, food and beverage, water filtration, etc. [www8]

Fig. 2.13 3000 Diameter Dish Head Polishing Machine [www8]

Table 2.2 Specifications for 3000 Diameter Dish Head Polishing Machine [www8]

Vessel Heads & Shell CNC grinding system from Ronazni

Grinding and polishing machine designed to work inside and outside vessel heads, shells and cones . The system is constituted from a manipulator with three axis commanded from a numerical control, where you can install one or two grinding units. The units those can mount an abrasive belt or a flap wheel made in cotton for the polishing. Both grinders are equipped with a pneumatic damping device. [www9]

Fig. 2.14 Radial grinding inside head, radial grinding outside head, circular grinding outside, beveling edge heads, edge heads preparation [www9]

Technical characteristics for standard plant:

CNC 3 axis manipulator

total rating 30 kW

manipulator strokes 4000 x 2500 mm ( horizontal x vertical )

grinding unit kW7.5

grinding unit kW3.0

3 turning machine: turning table, vertical positioner, motorized rollers [www9]

Fig. 2.15 Grinding and polishing machine with turning table [www9]

Welding Horizontal Rotary Table/Precision Table for CNC Milling

Quick Detail:

Headstock and Tailstock positioners generally handle the rotation of long work pieces around a horizontal centerline. The Headstock is generally powered and the Tailstock is free-wheeling with no other support under the work piece. Long complex structures can be turned to make the work execution easier for the welder. In some cases only a Headstock unit is required as shown in the pipe-spool fabrication arrangement depicted below. [www10]

Fig. 2.16 Welding Horizontal Rotary Table/Precision Table for CNC Milling [www10]

Description:

Head and Tailstock Positioners can be used for a variety of parts and suitable for long objects. Typically a Head & Tailstock Welding Positioner is used for long rectangular shapes that must be supported from both ends. Both fixed height rotation centerline and power elevating models are available for ergonomic placement of the weldment. Head stock-Tail stock Positioners capacity ranges up to 100 Tons and various flexibility in job handling. Other versions of machines available with variable height adjustments (center height adjustment to cater larger job swing) and other control possibilities. With a large rotation speed range all welding processes can be accommodated, such as MIG, TIG, SAW welding. [www10]

Applications:

Head and tailstock positioners provide both lifting and powered variable-speed rotation in either direction. The units are ideal for welding, torch cutting, or cladding operations. Idler tailstock positioners have the same specifications as the corresponding headstock positioners, except they are not powered. The two units may be spaced apart to accommodate a variety of work-holding fixture lengths. [www10]

Competitive Advantage:

Offer lifting and electromechanical rotation

Capacities from 1,000 kg. to 40 tons

Automatic computer-controlled leveling system accurate to ± 2 mm

Slide positioning for varying fixture lengths

Low-maintenance brushless motor

Easily accessible hydraulics for inspection and maintenance [www10]

The main objectives of the current bachelor thesis

The main objectives of the current bachelor thesis are following the design and manufacturing of a turning table for fixing conical and torispherical heads, with a view to polishing, used for tanks in beer industry.

The turning/rotary table is used for fixing and centring the conical and torispherical vessel heads. The turning table is an indispensable fixture device in the polishing process for this type of vessel heads.

The polishing of the conical and torispherical vessel heads is important after the rolling process. The rolling process deterioriates the surface of the metallic sheet and a polishing process is mandatory.

For this turning table the number of revolutions per minute can be set depending on the polishing required type.

The turning table is connected through a programmable logic controller (PLC) at polishing machine.

In Fig 3.1 is presented a photo with turning table manufactured within the company Inotec.

Fig. 3.1 Turning table for fixing conical and torispherical heads

The design of the turning table

The idea to design a turning table was defined in the moment when a coworker has been an exchange of experiences at a company from Italy named Meccanica Ronzani profiled on polishing and grinding were he saw the turning tables, take pictures and told me about this, with the ideea that in the company were I work was needed a turning table for polishing.

Fig. 4.1. First example of turning table from company Meccanica Ronzani

In the Fig 4.1 can be observed the model of the turning table for polishing interior of the heads. From this model of turning table I took over the centering mode, the idea with linear guides for fixing the head support,the idea of the body, I profiles and the principle of rotation for turning table.

Fig. 4.2 Second example of turning table from company Meccanica Ronzani

In the Fig 4.2 can be observed the model of the turning table for polishing exterior of the heads. From this model I took over the idea of the head fixing on the radius with devices with rolls.

I have concentated all the ideas of these models of turning table in a single concept and I was able to optimize and design turning table that is capable to fixing and centering the vessel heads for polishing interior or exterior surfaces.

Fig. 4.3 Turning table manufacture within the company Inotec

Assembly drawing of the turning table

The design of the turning table was realized in SolidWorks 2017 being manufacturing within the company Inotec. All the parts was designed in SolidWorks excepting gearmotor [Annex1], and liniar guides [Annex2] for which both the technical documentation and the equipment were purchased.

Following the component parts of the turning table will be presented and details about the steps of the design and technical drawings.

In the below figure is presented the 3D model of the turning table for fixing conical and torispherical heads.

Fig. 4.4 3D model of the turning table for fixing conical and torispherical heads

Design of components parts

In Fig. 4.5 is presented the base plate which is part of the body assembly. The base plate is realized from steel S 355 and is manufactured through laser cutting from a sheet metal with thickness 25 mm.

Fig. 4.5 3D model of base plate

The support plate is part of the body assembly, presented in Fig. 4.6 The support plate has the role for fixing gearmotor and fix part from crown gear. Is realized from steel S 355 and is manufactured through laser cutting from a sheet metal with thickness 25 mm. The holes for fixing gearmotor are clearance holes Ø 9 and the holes for fixing the fix part from crown gear are tapped M12.

Fig. 4.6 3D model of the support plate

The body assembly is realized through welding of 5 different parts presented in Fig. 4.7. The shell is realized cutting a pipe with exterior diameter Ø 762 mm and thickness 8 mm at height 200mm. The ribs have the role of strengthering the body. After welding the body is electrostatic painted to prevent rust.

Fig. 4.7 3D model of the welded body

In Fig. 4.8 is presented plate support for I profiles. The plate is realized from steel S 355 and is manufactured through laser cutting from a sheet metal at diameter Ø 1500 mm with thickness 25 mm. The plate has the role to fixing the I profiles and is fixed on the rotative part of crown gear. The holes are tapped M12. The plate is electrostatic painted to prevent rust.

Fig. 4.8 3D model of plate support for I profiles

In Fig. 4.9 is presented the assembly of the crown gear. This assembly of the crown gear has the role of the connection between the body of the table and the rotating parts. The crown gear is meshing with the gear shaft obtaining the circular motion of the turning table. It has the module 4.5, number of teeth is 101, face width is 46 mm and the outside diameter Ø 531. The gear crown was bought.

Fig. 4.9 3D model of crown gear

The gear shaft presented in Fig. 4.10 has the role to trasmit the rotations from gearmotor to the crown gear. The module of the gear shaft is 4.5, number of teeth is 12 and the face width is 46 mm. The gear shaft is fixed in gearmotor with a screw M10 and with a parallel key. The gear shaft is machined and is hardened and tempering, material of the gear shaft is 1 C 60.

Fig. 4.10 3D model of the gear shaft

In the Fig. 4.11 is presented the I profile on which is installed the linear guide. The I profile is manufactured from steel S 355. The I profile is electrostatic painted to prevent rust. The upper suface of the part is milling in order to ensure proper mounting of linear guide. The tapped holes are M8 at a distance of 80 mm.

Fig. 4.11 3D model of I profile

In the Fig. 4.12 is presented support plate which is part of the head support. The plate is realized from steel S 355 and is manufactured through laser cutting from a sheet metal with thickness 20 mm.

Fig. 4.12 3D model for support plate

The shaft from Fig. 4.13 has the role to support the rollers, is turned on lathe at the diameter Ø 12 and is tapped M12 at the ends on a length of 15 mm. The material of the shaft is C 45.

Fig. 4.13 Shaft for fixing rollers

In the Fig. 4.14 is presented the welded assembly of head support on which it is mounted rollers. On this head support is also welded the block from linear guide. After welding the head support is electrostatic painted to prevent rust.

Fig. 4.14 Head support welded

In Fig. 4.15 is presented a pentagonal part which has the role to sustain the head when it is polished on the interior surface. It is realized from polyamide PA 6 and is manufactured through water jet cutting.

Fig. 4.15 Pentagonal head support

In the Fig. 4.16 is presented an shaft wich has the role to centering and fixing the head. The shaft is realized from steel C 45 and is manufactured on the lathe.

Fig. 4.16 Centering head shaft

The liniar guide has the role to sutain and guide the head support in order to align the head support at the right diameter of the head. In the bellow table are presented the tehnical specifications of the linear guide used.

Fig. 4.17 Specification of the liniar guide [www11]

Assemby steps

After all components of the turning table are manufactured the next steps for assembly are follow:

In the first step of the assembly process all the parts from body of the turning table are welded as shown in Fig. 4.18.

Fig. 4.18 3D model of the first step in the assembly process.

In the second step in the assembly proccess the gear shaft is assembled in the gearmotor with a key and is fixed with an M10 screw. The gearmotor with the gear shaft is fixed on the body of the turning table with 8 x M8 screws with hexagonal head as shown in Fig. 4.19.

Fig. 4.19 3D model of the second step in assembly process

In the Fig. 4.20 is presented the third step of assembly procces which consists in positioning 14 x M12 screws with hexagonal head on the fix part from the crown gear. After that the rotative part from the crown gear is fixed on the plate support for I profiles with 16 x M12 screws with hexagonal head.

Fig. 4.20 3D model of the third step in assembly process

The fourth step in assembly process consists in screwed the screws that were positioned on the fix part from the crown gear on the body of the turning table. A difficulty in this step is to position the screws from the crown gear on the body of the turning table as shown in Fig. 4.21.

Fig. 4.21 3D model of the fourth step in assembly process

In the fifth step I profiles are assembled on the plate with M12 screws with hexagonal head. After that the supports for the pentagonal support head are welded on the interior end of the I profiles as shown in Fig. 4.22.

Fig. 4.22 3D model of the fifth step in assembly process

The next step is to assembly the linear guides with M8 socked screws. After that on the holes from linear guides are placed covers to protect from metal powder resulting from polishing process. Fig . 4.23.

Fig. 4.23 3D model of the sixth step in assembly process

In Fig. 4.24 the seventh step in assembly process is presented and consists in welding the head support and assembly the rollers and all other parts from head support and then positioning them on the linear guides.

Fig. 4.24 3D model of the seventh step in assembly process

In this step on the plate support for I profiles is welded a tapped part in which is screwed the centering head shaft as shown in Fig. 4.25 The pentagonal head support is also mounted with 10 x M6 screws with hexagonal head.

Fig. 4.25 3D model of the eigth step in assembly process

The last step consists in fixing a shell band from stainless steel with M6 socket screws on the I profiles. This band has the role to prevent the accidents at work when the turning table is working. Fig. 4.26.

Fig. 4.26 3D model of the ninth step in assembly process

In the below figure is presented a detail how the shell band is fixed on the I profile.

Fig. 4.27 Detail how the shell band is fixed on the I profile

Technological itinerary of the gear shaft

Presentation of the PLC panel interface

In the window below is presented the main menu of the machine in which it can navigate in order to set the work parameters of the turning table.

Fig. 5.1 The main menu from the PLC panel

In this menu the work parameters of the CNC machine can be manually set to do simple and fast machining works or to do various tests.

Fig. 5.2 Manual mode menu of the PLC panel

In this menu we can choose the position of the vessel head considering that the turning table is designed to can fix the vessel head on the exterior or interior surface.

Fig. 5.3 Choose the position of the vessel head menu of the PLC panel

In the following considering that we have chosen the positioning with the exterior part of the vessel head, we can process the 3 types of vessel heads as shown in below figure. For the exterior the machining is made from the right to left meaning that the first point of the polishing machine is at the basis of the head in right and the last point is in center of the head.

Fig. 5.4 Choosing shape of the vessel head

By touching the torispherical vessel head button, in below window can be sets the work parameters of the CNC.

Programming steps:

The polishing head of the CNC is positioned gradually on the marked areas with X as shown in below figure so that the program collecting the dimensions and both radius of the vessel head ready for polishing.

The work machine parameters are set. The machine feed for each section represented in below figure as well as the revolutions of the turning table and polishing band.

Fig. 5.5 Exterior torispherical vessel head of PLC panel

By touching the conispherical vessel head button, in below window can be sets the work parameters of the CNC.

Programming steps:

The polishing head of the CNC is positioned gradually on the marked areas with X as shown in below figure so that the program collecting the dimensions and radius of the vessel head ready for polishing.

The work machine parameters are set. The machine feed for each section represented in below figure as well as the revolutions of the turning table and polishing band.

Fig. 5.6 Exterior conispherical vessel head of PLC panel

By touching the conical vessel head button, in below window can be sets the work parameters of the CNC.

Programming steps:

The polishing head of the CNC is positioned first in point one and second in the point two on the marked areas with X as shown in below figure so that the program collecting the dimensions of the vessel head ready for polishing.

The work machine parameters are set. The machine feed represented in below figure as well as the revolutions of the turning table and polishing band.

Fig. 5.7 Exterior conical vessel head of PLC panel

In the following considering that we have chosen the positioning with the interior part of the vessel head, we can process the same 3 types of vessel heads as shown in Fig. 5.4 For the interior the machining is made from the left to the right meaning that the first point of the polishing machine is at the basis of the head and the point 3 is in center of the head.

By touching the torispherical vessel head button, in below window can be sets the work parameters of the CNC.

Programming steps:

The polishing head of the CNC is positioned gradually on the marked areas with X as shown in below figure so that the program collecting the dimensions and both radius of the vessel head ready for polishing.

The work machine parameters are set. The machine feed for each section represented in below figure as well as the revolutions of the turning table and polishing band.

Fig. 5.8 Interior torispherical vessel head of PLC panel

By touching the conispherical vessel head button, in below window can be sets the work parameters of the CNC.

Programming steps:

The polishing head of the CNC is positioned gradually on the marked areas with X as shown in below figure so that the program collecting the dimensions and the radius of the vessel head ready for polishing.

The work machine parameters are set. The machine feed for each section represented in below figure as well as the revolutions of the turning table and polishing band.

Fig. 5.9 Interior conispherical vessel head of PLC panel

By touching the conical vessel head button, in below window can be sets the work parameters of the CNC.

Programming steps:

The polishing head of the CNC is positioned first in point one and second in the point two on the marked areas with X as shown in below figure so that the program collecting the dimensions of the vessel head ready for polishing.

The work machine parameters are set. The machine feed represented in below figure as well as the revolutions of the turning table and polishing band.

Fig. 5.10 Exterior conical vessel head of PLC panel

In the menu from the below figure are presented the work parameters of the CNC which are accessed from the main menu for the calibration of the equipment

Fig. 5.11 The calibration window of the PLC panel

Conclusions

Main benefits:

Most of the parts have benn manufactured within the company, this has led to the reduction of the costs for buying a new equipment.

This turning table has been assembled and mounted on a PLC with the polishing machine.

Automating of the polishing process which until now was manually.

Fig 6.1 Turning table and polishing machine connected to a PLC panel.

Perspectives:

In the future, we want automation the head supports through installation of a system of racks controlled by CNC so by entering the diameter of the vessel head, the head supports to be positioned automatically at that diameter.

Fig. 6.2 Head support with rolls

Bibliografy

[www1] – http://www.inotec.com.ro

[www2] – https://www.slideshare.net/SHUBHAMUJJ/design-and-fabrication-of-poka-yoke-pneumatic-fixture-for-milling-and-shaper-machine

[www3] – http://www.nitc.ac.in/dept/me/jagadeesha/mev303/CHAPT_INTRODUCTION_TO_JIGS_AND%20FIXTURES.pdf

[www4] – https://en.wikipedia.org/wiki/Polishing_(metalworking)

[www5] – https://ro.pinterest.com/pin/692498880174285359/?lp=true

[www6] – https://www.globalspec.com/learnmore/manufacturing_process_equipment/abrasives_grinding_finishing/grinding_machines_finishing_equipment/polishers_buffing_machines

[www7] – http://es.jotunpolishing.com/index.php/Polish-Buffing-machinery/2017/04-18/46.html

[www8] – http://www.jotunmachinery.com/dish-head-polishing-machine/dish-head-polishing-machine.html

[www9] – http://www.meccanicaronzani.com/index.php?id=impiantosmerigliaturacnc&L=1

[www10] – http://www.pipe-weldingrotator.com/sale-1957955-welding-horizontal-rotary-table-precision-table-for-cnc-milling.html

[www11] – https://www.hiwin.de/en/Products/Linear_Guideways/Series_HG_QH/Block_HG/HGW/4277

[CHI 16] – Chiara De Giorgia, Valentina Furlana, Ali Gökhan Demira, Elena Tallaritab, Gabriele Candianib, Barbara Previtalia, “Laser micro-polishing of stainless steel for antibacterial surface applications”, Procedia CIRP 49 (2016) 88 – 93

Opis

Number of pages: 80

Number of figures: 57

Bibliography references: 12

Poster

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