Nauka i Obrazovanie (Jan 2015)
Elaborating and Making Rational Decisions in Designing Process Operations of a Group of Holes
Abstract
To manufacture engineering products are used expensive multi-purpose CNC machines with five operated coordinates, allowing a single setup of the work-piece to process a group of holes in the housing part from all sides.Because of the haphazard arrangement of a large number of holes available in the space it is difficult to ensure the effective use of these machines.Onsite operational research, conducted on six CNC GS-500 models, involved actual observations and time measurements during 15 working shifts, processing of observation results, and calculations of equipment performance parameters such as machine utilization rate, arrangement and changeover time loss, and real output. Time loss (downtime) because of arrangement amounted 44.52%, while that of due to changeover was 20.1% of the total downtime value. These downtimes hide irrational design solutions concerning the engineering process and a large number of changeovers for a new operation to process a group of the specified work-pieces.It is found that to reduce the changeover downtimes it is necessary to increase, first of all, the average number of single tool travels per one setup in generalized characteristics of a group of the work-pieces. That means to increase a changeover concentration of processing within a single operation, as well as to choose rational values for machining a batch of the work-pieces. Under study conditions, it is, at least. 20-50 pieces.To implement a development of the principle of increasing concentration of the processing changeovers it is advised to apply the developed mathematical models, algorithms, and programs that can be used, as modules or their parts, in computer-aided design (CAD) systems. This allows a 3-5 times reduction in time to find the rational option of the work-piece position on the machine work surface when developing a process technology, a review and an analysis of more than the usual number of such possible options. It also improves the quality of adopted design solutions. This is the possible way to reduce the downtimes for organizational reasons.The described technique to conduct operational research and define statistical performance parameters of automated sites and individual CNC machines can be used for business reorganization with modified process and management structure.
Keywords
