OptiSonic: The Latest in Ultrasonic Machining Technology. Presented By: Mike Cahill Mechanical Engineer

Transcription

1 OptiSonic: The Latest in Ultrasonic Machining Technology Presented By: Mike Cahill Mechanical Engineer

2 Outline OptiPro Company Overview OptiSonic Platform Overview Introduction to Ultrasonic Typical Applications OptiPro OptiSonic Holder IntelliSonic Software Testing Results Additional Platform Information Questions

3 OptiPro Overview years in business 30,000 square foot facility in Ontario, NY OptiPro Team = 70 employees 10 Mechanical Engineers 4 Software Engineers 3 Electrical Engineers 2 Process Engineers 6 Process Technicians / Opticians 3 Machinists 10 Machine Assembly Technicians 6 Service Technicians 4 Mastercam Support and Training 10 Office Sales & Marketing Etc

4 Temperature Controlled Machine Manufacturing 4

5 Advanced Process Development Lab (APD) 5

6 Climate Controlled Metrology Lab New environmentally-controlled metrology lab Supports research for our SBIR s with the NAVY & NASA, IRAD and customer demonstrations 6

7 OptiSonic 3X/5X Ultrasonic Machining Technology for Optical Glasses and Ceramics 3 to 5 Axis Capability in 4 different size platforms Fagor CNC Control Simple Windows-based Graphical User Interface (GUI) OptiPro s IntelliSonic Technology Quick Change High Speed Tool Spindles Liquid Cooled/Coolant Through Spindle Standard 24-tool Carousel Automatic Tool Changer on 3X Model, Different ATC Configurations Available on 5X Model Tool Setting Probe/Work Probing System Laser Tool Probe Optional 7 Ethernet & USB Communications

8 Why Ultrasonic? Grinding hard glass and ceramics produces accelerated tool wear. Flat Edge Tooling will develop flat edges, tapers, and continually become dull. Processing speeds are slow due to unwanted tool load and potential part breakage. Grinding parts to the correct size is difficult with harder ceramics. 8 Polishing optics can become more time consuming due to the roughness of the part.

9 What is Ultrasonic? Process Force Reduction Increased Processing Speeds Tool Wear Reduction Improved Surface Quality

10 10 OptiSonic Tool Holder Overview

11 Applications Typical Applications: Lightweighting with thin walled features Core Drilling Generating Spheres & Aspheres Free Form Rastering Deep Drilling Common Materials: BK7 Zerodur Fused Quartz Fused Silica Pyrex ALON Zirconia PCA Sapphire Other glass and ceramics

12 OptiSonic Spindle All power transfer occurs within the housing. Labyrinth seal ensures no coolant gets into housing during machining processes. Air Purged housing

13 IntelliSonic Frequency Sweep Software will automatically sweep through a range of frequencies to determine the ideal frequency to run each tool at. Users can load and characterize new tooling with ease. CNC integration Full integration into the Fagor Tool Library. Attributes set during the characterizing of a tool can be easily stored within the tool library. MCodes are able control all necessary Ultrasonic functions. 13 Adaptive Frequency Control Frequency will automatically adjust to the changing conditions inside the part and ensure the tool is kept at the optimal cutting condition. This ensures consistency throughout the part.

14 IntelliSonic

15 IntelliSonic

16 Core Drilling Comparison 16 Two runs were made, first with ultrasonic off then with it turned on. Both of these tests were performed at the same feed rate. Material: Fused Quartz Data measured using a Kistler 9257B 3-Axis force dynometer

17 Long Core Drill Used a Ø4mm OD by 225mm long core drill Using the ultrasonic oscillation and a high pressure CTS pump to effectively evacuate the swarf and keep the tool cooled Fast feed rates without a pecking routine in BK7 Less than 10 microns of taper over the length of the core Finished part was a Ø2.490mm by 190mm long core 17

18 Lightweighting/Thin Webs 1mm wall thickness on both webs and outside wall Minimal edge chipping All programmed using MasterCam

19 Tool Wear Comparison Took two tools of the same grit and size to perform a comparison test Each tool was used to remove the same amount of material Tool 1 was utilized with Ultrasonic off, while tool 2 was utilized with Ultrasonic on 1 2

20 Tool Wear Comparison 1 Ultrasonic off 2- Ultrasonic on

21 Platform Information Available in 3, 4, and 5 Axis models Table Axis can be configured as a work spindle or a C or A-Axis Wide variety of machine sizes and configurations Coolant filtration and circulation standard Standard collet holders available for non-ultrasonic operations

22 For More Information Technical Information: Mike Cahill Office: OptiPro Systems, LLC 6368 Dean Parkway Ontario, NY Sales Information: Dave Mohring Office: x232