Development of a novel zero point setting device for high speed and micro machining applications

In CNC machining, high downtimes of machine tools are associated with the tool zero point setting in the absence of automatic setting devices. The problem is more acute in high speed and micro-machining processes dealing with micron and sub micrometer range depth of cut which precise require zero po...

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Main Authors:	Amin, A. K. M. Nurul, Mahmud, Md. Asif, Arif, Muammer Din, Derus, Nur Hidayah, Khamis, Siti Salwa
Format:	Conference or Workshop Item
Language:	English
Published:	2012
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://irep.iium.edu.my/17681/ http://irep.iium.edu.my/17681/ http://irep.iium.edu.my/17681/1/ID_1603_Prof._Amin_Novel_Tool_Zero_Point_Setting_Device.pdf

id	iium-17681
recordtype	eprints
spelling	iium-176812012-04-10T00:52:59Z http://irep.iium.edu.my/17681/ Development of a novel zero point setting device for high speed and micro machining applications Amin, A. K. M. Nurul Mahmud, Md. Asif Arif, Muammer Din Derus, Nur Hidayah Khamis, Siti Salwa TJ Mechanical engineering and machinery In CNC machining, high downtimes of machine tools are associated with the tool zero point setting in the absence of automatic setting devices. The problem is more acute in high speed and micro-machining processes dealing with micron and sub micrometer range depth of cut which precise require zero point setting. Hence there is a high demand for reliable and cost-effective zero-point setting devices. The majority of conventional, and some CNC, machine-tools do not have an integrated zero point setting device. Therefore, the determination of the zero point during metal cutting is currently done by a trial and error method and the accuracy of positioning of the tool especially in the case of micro-machining is not satisfactory and poses a challenging problem. The available zero point setting devices are extremely sophisticated electronic instruments, which are very expensive with unit prices ranging up to US$ 30,000. Also, the operation of such devices demands very skilled machinists and trained operators. The novel zero-point setting system, developed by the authors, uses the available equipments in a normal machining laboratory to detect the zero point with a good degree of accuracy and repeatability. One of the terminals of the device is connected to the tool holder and the other to the work-piece fixture using screws. When physical contact is established, between the tool and the work-piece/fixture element, a flashing LED light and a sounding buzzer are activated indicating that the circuit has been closed and the tool zero point is attained. The electric circuit arrangement of the device ensures high sensitivity to actual physical contact and a minimum resolution which is equal to the relevant machine’s minimum move (less than 0.1 μm for grinding operations). Thus, this device can play a vital role for precisely setting the zero point (or starting point) for micro-machining, and reducing the non-productive downtime of machine-tools and extra training of the relevant personnel. The total expenditure for the construction of this device was about RM 50 and it can be easily attached to vertical and horizontal milling machines, drilling machine, grinders, lathes, or machining centers. It can also be used with non-conductive work-pieces like glass, plastic and ceramics. Therefore, with this cost effective, reliable, and accurate device it is possible to make manufacturing processes more precise, rapid, economical, and productive. 2012 Conference or Workshop Item PeerReviewed application/pdf en http://irep.iium.edu.my/17681/1/ID_1603_Prof._Amin_Novel_Tool_Zero_Point_Setting_Device.pdf Amin, A. K. M. Nurul and Mahmud, Md. Asif and Arif, Muammer Din and Derus, Nur Hidayah and Khamis, Siti Salwa (2012) Development of a novel zero point setting device for high speed and micro machining applications. In: IIUM Research, Invention and Innovation Exhibition 2012 (IRIIE 2012), 21 - 22 February, 2012, Kuala Lumpur, Malaysia. (Unpublished) http://www.iium.edu.my/irie/12/
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Amin, A. K. M. Nurul Mahmud, Md. Asif Arif, Muammer Din Derus, Nur Hidayah Khamis, Siti Salwa Development of a novel zero point setting device for high speed and micro machining applications
description	In CNC machining, high downtimes of machine tools are associated with the tool zero point setting in the absence of automatic setting devices. The problem is more acute in high speed and micro-machining processes dealing with micron and sub micrometer range depth of cut which precise require zero point setting. Hence there is a high demand for reliable and cost-effective zero-point setting devices. The majority of conventional, and some CNC, machine-tools do not have an integrated zero point setting device. Therefore, the determination of the zero point during metal cutting is currently done by a trial and error method and the accuracy of positioning of the tool especially in the case of micro-machining is not satisfactory and poses a challenging problem. The available zero point setting devices are extremely sophisticated electronic instruments, which are very expensive with unit prices ranging up to US$ 30,000. Also, the operation of such devices demands very skilled machinists and trained operators. The novel zero-point setting system, developed by the authors, uses the available equipments in a normal machining laboratory to detect the zero point with a good degree of accuracy and repeatability. One of the terminals of the device is connected to the tool holder and the other to the work-piece fixture using screws. When physical contact is established, between the tool and the work-piece/fixture element, a flashing LED light and a sounding buzzer are activated indicating that the circuit has been closed and the tool zero point is attained. The electric circuit arrangement of the device ensures high sensitivity to actual physical contact and a minimum resolution which is equal to the relevant machine’s minimum move (less than 0.1 μm for grinding operations). Thus, this device can play a vital role for precisely setting the zero point (or starting point) for micro-machining, and reducing the non-productive downtime of machine-tools and extra training of the relevant personnel. The total expenditure for the construction of this device was about RM 50 and it can be easily attached to vertical and horizontal milling machines, drilling machine, grinders, lathes, or machining centers. It can also be used with non-conductive work-pieces like glass, plastic and ceramics. Therefore, with this cost effective, reliable, and accurate device it is possible to make manufacturing processes more precise, rapid, economical, and productive.
format	Conference or Workshop Item
author	Amin, A. K. M. Nurul Mahmud, Md. Asif Arif, Muammer Din Derus, Nur Hidayah Khamis, Siti Salwa
author_facet	Amin, A. K. M. Nurul Mahmud, Md. Asif Arif, Muammer Din Derus, Nur Hidayah Khamis, Siti Salwa
author_sort	Amin, A. K. M. Nurul
title	Development of a novel zero point setting device for high speed and micro machining applications
title_short	Development of a novel zero point setting device for high speed and micro machining applications
title_full	Development of a novel zero point setting device for high speed and micro machining applications
title_fullStr	Development of a novel zero point setting device for high speed and micro machining applications
title_full_unstemmed	Development of a novel zero point setting device for high speed and micro machining applications
title_sort	development of a novel zero point setting device for high speed and micro machining applications
publishDate	2012
url	http://irep.iium.edu.my/17681/ http://irep.iium.edu.my/17681/ http://irep.iium.edu.my/17681/1/ID_1603_Prof._Amin_Novel_Tool_Zero_Point_Setting_Device.pdf
first_indexed	2023-09-18T20:26:40Z
last_indexed	2023-09-18T20:26:40Z
_version_	1777408462663188480

Development of a novel zero point setting device for high speed and micro machining applications

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