Study and implementation of a Metalworking workshop

Tiago S. Amaral
Instituto Superior Tcnico, T. U. Lisbon, Portugal

E-mail: Amaraltiago@live.com.pt

Abstract
The schools of engineering support several research and technical -scientific development activities of its teachers, researchers and students, through several experimental multi-disciplinary skills installed in specialty workshops. A perfect example of such skills can be the glass workshops because it allows the development of specific applications for storage, heating, mixture of liquid and / or gas. Electricity workshops are another good example because allows the implementation of instrumentation and / or automation of test benches. The mechanical workshops also allow the components and systems manufacture for positioning, support and handling of equipment and various substances. This work was developed around the definition and the establishment of mechanical workshops for the manufacture of components and mechanical systems used in supporting the investigation and research activities development in engineering schools. This kind of activity is classified for reduced or batch manufacturing unit, components characterized by highly complex geometries with tight dimensional and geometric tolerances, sometimes associated with the processing of non-traditional materials. Its also important that we observe the workshops framework in a multidisciplinary academic environment with high technical and scientific creativity, where the technical terminology is opulent but where theres is sometimes a lack of knowledge of the practice of design and technical drawing as basic elements for the development of components and mechanical systems. The current thesis develops around the study and implementation of a mechanical workshop, emphasizing the various peculiarities concerning to the implementation procedures, the equipment selection and the hygiene and safety rules.

Keywords: mechanical workshop, Installations, Machine Tools, Selection of equipments, Layout.

Introduction
The theme of the study is the implementation of operating and procedure for a structure that allows modern workshop to support the experimental development of teachers, researchers and students of IST. It was then necessary to understand the needs of the entire school and set the objectives proposed for the formation of a workshop (NOF). It should be noted that, previously, all support was

provided by mechanics technology laboratory (MTL) and other workshops that are spread around the campus of IST. There are many departments with workshops that provide assistance to investigators, but they arent fully equipped nor provide the same services. However, there are many departments without any workshop support. This matter leads to resorting to MTL or other workshops, which are not part of their function. For the NOF to be able to give the same support that the MTL, the executed products must cover a wide range of products with complex geometries and multiple dimensions and the final products need to have a wide range of materials as well as high precision and finishing levels. The concept of technology on the NOF would have to approach the concept used in the MTL. In order to begin the project, it was necessary to recognize the capabilities of space and equipment at IST: After gathering the needs of the various research groups, there is a need to classify the different projects that may be part of the products list manufactured by NOF. It was necessary to identify the product from the standpoint of material, geometry, finishing, precision and quantities. The materials used in manufacture, such as polymers and steel and aluminum alloys, have great representation in most applications. However, there is a group of other high mechanical resistance materials and alloys such as nickel super-alloys and ceramic. In general, the products are from revolution geometries or drilled boxes. These geometries can be manufactured through the use of individual or combined operations of turning and milling. However, there are several exceptions such as inside corners with a small radius, small diameters and deep holes, which mean that the institution has to consider the type of technology to be introduced into NOF. Another important aspect is the development and study of complex geometry products that are introduced in the project in the form of mathematical equations. So, the key to this problem is to use numerical control technology in its manufacture. It is essential not to overlook the fact that often there is a need for mass fabrication when we refer to test specimen. For various material characterization tests is necessary an equality of geometrys order which leads again to the need of using numerical control technology.

Workshop Definition
A metalworking workshop is equipped with several equipment as machine tools, hand tools, furniture, equipment handling tools and lifting material tools so as human resources. No less important, it consists on a space with an infrastructure that provides support to the machines and good working conditions. Infrastructure - needs to be equipped with adequate conditions for the activitys execution and allow the installation of machine tools, air renewal points, compressed air, HVAC, water supply, the lighting. It has to provide basic circumstances for technicians to have good working conditions. Study interior - The colors could not be ignored as a factor, as our project includes employment, it is intended to build not only a workshop but also a workplace. Therefore, the color choice is an important risk factor. It should be taken into account the color of light, but also the color of the walls, floor and ceiling.

Pavements - The Industrial pavements are the ones that suffer most wear so it needs to be highly resistant. The multi-layered pavement epoxy is the solution to make it textured and smooth with high strength and anti-slip required in order to fulfill that, in portaria n. 987/93, de 6 de Outubro [1] HVAC and ventilation - are important factors related to human productivity and can be obtained in two forms: natural and artificial ventilation. Natural ventilation is achieved by the installation of windows, but when it is insufficient to provide a pleasant sensation due to other problems such as dust, external noise and frequent periods of rain, it leads to the use of artificial ventilation. It is necessary that ventilation gives comfort to all employees and in case of processes with waste smokes is convenient to use extraction air points, for the safety of all employees. In the installation of HVAC it is necessary to consider the energy point that power the system, a point on the outside for exhaust air and a condensate output. Power supply and lighting - as comfort and safety rules, we must follow the Portaria n. 949-A/2006 11 September Technical Rules of Low Voltage Electrical Installations,[2]. Lighting installations in the workplace are an important aspect of safety and varies according to the type of work. Compressed air, water and sewers perform an important role in the workshops operation. Compressed air is an essential factor in the operation of machine tools, which in the case of milling machines; usually, this type of equipment needs to have an available pressure of 6 bar [2]. The water and the sewers provide the means to have a clean workshop.

Implementation of Facilities
The layout can be defined as the physical arrangement of equipment, including the space required for material handling, storage, and all other activities and services. Due to the many aspects, it is an issue which solution can achieve high levels of complexity. The execution of a layout can be described in four phases. They are presented in (Table 1) Each phase has several steps to take after reviewing the table and our project is necessary to take account what step to consider.
1 fase
Determine what will be produced Determine how much will be produced Determine which components will be made or purchased Determine required operations Determine sequence of operations
Get the default time of each operation

3 fase Identify needs for support staff Identify the needs of the infrastructure Identify total space requirements 4 fase
Building master plan Gather the Technical leaders to make the necessary adjustments Building a relationship of financial resources Obtain approval of the hierarchy maximum Implement the project Make the start of production
Collect data to test the system

2fase Determine the work area Determine the number of machines required Determine the flow requirements Determine all existing operations Plan the post of operations

Table 1 Phases of layout execution

Equipments
The devices are divided into numerous categories: there is furniture, equipment handling and lifting materials and mainly machine tools, an essential part of a workshop designed to modeling material, just by moving mechanically a set of tools [3].

The machine tool is mainly divided into two categories, conventional they reach details of the hundredth of a mm, more suitable for products that are less complex and less accurate [4].Usually these solve the problems that most products have in their manufacture, they execute revolution products, opening boxes, threaded holes, among others. However it is often necessary to use a different category of machine tools, which are the computer numerically controlled or CNC, machines with high precision accuracies, covers about one thousandth of an mm. It gives the ability to store many programs in memory, reducing human error, and increasing the accuracy and complexity of the final product [5]. Given such precision, installation and improper operation can affect the accuracy, stability and working time. For the installation of a machine tool is necessary to note the power supply, knowing that they are compatible to the network; the compressed air supply plays a vital role to the performance of the machine tools, lubrication of all the equipment components applying the quality and quantity of oil specified in each manual, and taking care of vibrations by promoting accessory to combat this problem.

Evaluation Criteria
A criterion purchase is always necessary to support the choice of the goods acquired, for this is essential to use a model to evaluate the proposals. The model evaluation is to assess the proposals partially, subdividing the entire evaluation in sub-factors, that after the sum of the partial evaluations, a global score is obtained. The expression given on figure 1 is the representation of the mathematical evaluation.
Incognit v(p) n Fi C i(p) Definition Global Punctuation of the proposal Numbers of evaluated factures Coefficient de pondering Proposal Punctuation related to factor i factures

Figure 1 Mathematical expression of the application of the evaluation method

Equipment
Since one of the objectives was to innovate and renovate the workshop, it was necessary to renew all existing equipment and, after that, combat the main failures of the workshop. So it was necessary purchase machine tools assisted by computer. Therefore, it was necessary a study of all advantages features and costs to take into consideration, so that later we choose the most appropriate equipment.

CNC Milling Machine Center

The milling machine (Figure 2), divided into two subcategories (Figure 2 b)). In our case, the choice would be a vertical milling machine without feeder. In Figure 2 c)) we can see what kind of products can perform a milling machine and its complexity, and in Figure 2 d) we can see some of the main characteristics of a milling machine center.

Milling machine CNC

Horizontal Axis

Vertical Axis

with feeder a) Characteristics: Dimensions of table; Courses; Velocity de rotation principal axis; Weight supported by the table; Controllers; Precision; c) d) b)

without fedeer

Figure 2 Milling machine center; a) Division by subcategories of a milling machine; b) example of a 6 axis milling machine center[6]; c) principal characteristics of a milling machine center; d) Products executed by a milling machine center [6] [7];

A market study was made (Graph 1) to learn about the average price with IVA of a milling machine, in order to understand the range of values that we will work, just taking as criteria the 5 axis and the maximum height of 2850 mm. 200% p e r c e n t a g e 160% p r i c e 120% 80% 40% 0% Tecmill - vc 750 Tecmill - U5 - Emco - emcomill Maquinar Mais 620 450 DMU 50 eco

Millingde Maquinagem Centro Machine Center

Graph 1 market study of a milling machine center with similar characteristics.

After this superficial study was conducted, a study to three machining centers with the lowest value among themselves was made, comparing their features to figure out which equipment to purchase.

CNC Lathe Machine Center

The CNC lathe machine (Figure 3)) is divided into several subcategories (Figure 3 b)) in our case the choice would fall upon a CNC lathe machine with horizontal axis and simple tail. In Figure 3 c) and d) we can observe some characteristics and some final products prepared by this equipment.

CNC lathe machine

vertical axis

horizontal axis

simple spindle

spindle and tailstock spindle

Multiple spindle

a) Characteristics:

b)

Diameter turning; Length turning; Velocity of the rotation axis; Power tools; Courses; Controllers; Precision; c) d)

Figure 3 CNC lathe; a) division by subcategories of a CNC lathe; b) CNC lathe [7]; c) principals characteristics; d) Product executed by CNC lathe with c axis [8]

There were made a few analyses of accessories such as: Axis C, feeder, system that collect products, system pre-installation tool systems, tool support, Ethernet interface. A study of the market was made (Graph 1) to learn about the average price with IVA of a milling machine, in order to understand the range of values that we will work, just taking as criteria the range of diameters similar to those found in conventional lathe that already exist in the workshop, and with the optional C-axis tool or motorized

200%
p e r c e n t a g e p r i c e

160% 120% 80% 40% 0%

Tecmill - Tecnimpor - Tecnimpor - Deibar - HIT spinner tc Doosan hartford - 160 400 Lynx 220 MVP-8AD Dmg ctx310 Emco Emcoturn E45

CNC Lathe Machine Center Centro de Torneamento

Graph 2 market study of an lathe CNC machine

EDM Drilling Center

The EDM is divided into several subcategories (Figure 4 a)), our choice fell on the EDM for drilling (Figure 4 b)) because we already have the other two EDM. Each subcategory has its own special, accessories are not an item that you can buy and attach to the original. This is not about choosing the one that interests us but to acquire the various centers. These machines do not compete between

them but complement themselves, we can see in Figure 4 c) some principal characteristics, and Figure 4 d) some final products.

EDM Center Drill

Penetration

Wire

a) Characteristics: Profound maxima; Diameter do electrode; Piece weight; Dimension of the table; Courses; Filters; c) d)

b)

Figure 4 EDM center; a) Subcategories; b) EDM drilling center [9]; c) principals characteristics; d) Product executed by EDM drilling center [7] [9]

A market study was made (Graph 3) to learn about the average price with IVA of a milling machine, in order to understand the range of values that we will work, just taking as criteria the same range of values of 2 Classic Angiecut a machine tool that NOF possessed, as table size, and diameter of the electrode. 240% p e r c e n t a g e 200% 160% p r i c e 120% 80% 40% 0% Agie - charmilles Deibar - DZNC S- Ona - sd - 325 - drill 20 26 Electroerosao Furaao EDM Drilling Center
Graph 3 market study of an EDM drilling center

Tecmill - koton kth 205

Laser Machine Center

The laser machine (Figure 5) will bring to the workshop greater accuracy and detail, with higher quality than most conventional processes. The laser has the ability to operate very complex cutting profiles

and very small radius of curvature, reduces production costs (without additional costs of other consumables or need for further polishing and finishing), clean technology and it has a pollutant free process. Recording or laser cutting can be performed on almost any type of material and can be customized with an unparalleled precision and speed in a programmable and final way [10].
Laser Machine

3D laser machine

2D laser machine

Mobile machine

Fixed machine

a)

b) Characteristics: Type of laser (co2, YAG/YV04, UV); Working Area; Laser power; Precision; c) d)

Figure 5 laser machine center; a) laser machine [10]; b) subcategories; c) Product executed by a laser machine [10]; d) principals characteristics;

These machines also have several options that need to be assessed. We highlighted a few: the exhaust system, a table with underneath suction for cylindrical rotation system, Z-axis automated cooling system. A market study was conducted (Graphic. 4) in order to acquaint the average price with IVA of a laser machining center, using as criteria the cut sheet and recording. 320% 280% 240% 200% 160% 120% 80% 40% 0% Lasermaq smark 500 c Portlaser - gx 40 w Trotec - speedy Trotec - speedy 100 R 300

p e r c e n t a g

e p r i c e

Laser Machine Center a Laser Centro de Maquingem

Graph 4 market study of a laser machine center

Implementation of Space
The implementation was done according to the rules of the functional layout. It was necessary to decide how many sections and which of those should we divide the workshop; the proposal is to divide

into five sections. The first section is for material preparation and unconventional manufacturing, where it occurs welding and grinding, machines that unleash residues such as EDM centers (due to the smoke released that comes from the oil bath that the part is involved during the process), preparation of material (saws). The second section is the conventional section, where its used the concept of manufacturing cell, the proposal is to subdivide into multiple cells of various dimensions due to manufacturing range with machines that the NOF possesses. These cells are composed by a conventional lathe, a conventional milling machine, a drilling machine and a workbench. The third section is a CNC section, that will be composed by a CNC lathe, a CNC milling machine, and later by a laser machine or others CNC machines, it manufacture parts with great complexity and precision. The fifth section, the assembly and adjust parts section, is a large area with a bench and well provided of tools. Finally, the metrology and planning section will be an area for pieces verification, regular meetings, project planning and receiving customers in the workshop. All this division was made taking into account the use of a circulation path that respects the legislation of approximately 1200 mm.

Figure 6 Implementation do 3D space

The proposal for the distribution of the entire infrastructure to support NOF is to install rails placed on the ceiling of the NOF, in order to not restrict the space, and that future machine tools acquisitions do not alter the infrastructure.

Figure 7 Distribution of the various components of infrastructure

After the execution of the layout, appears different factors that pending on the location of such machines, the power to assign to each point of energy, where to place necessarily water and

compressed air points, although the objective of the proposal is to spread throughout the workshop so that any space can be changed when there is a need for it.

Conclusions
Similar to what is happening in many companies, a centralization of services is taking place, which results in less waste of equipment and human resources. There is a greater standardization of processes and improved efficiency in communication. The work on this project solves an old problem because now all the departments have access to the same resources and services. After performing a market study, to determine which companies performed the maintenance of such equipment with a good price, it follows that many of these rejected the proposed work due to the condition of working with the Portuguese State. This type of study was important, not only in the execution of the desired maintenance, but also in the creation of a working partner for the future, so they can provide mutual technical assistance and lower costs. We also conclude that the installation of rails along the ceiling was the best option for the distribution of the electricity grid among others because it will confer to the NOF more flexibility in space, similar to what happens in industry. This work allowed structuring a workshop to solve the manufacturing problems of the teachers, researchers and students of the Instituto Superior Tcnico.

References
[1] Portaria 987/93 6 de Outubro de 1993, relativa s prescries mnimas de segurana e sade nos locais de trabalho [2] Tavares, Andr, Estudo tcnico para estabelecimento de procedimentos de actuao, higiene e segurana em oficina metalomecnica, IST, Lisboa, 2011 [3] Dicionrio da Lngua Portuguesa, Porto Editora (2010) [4] http://www.mundocnc.com.br (19/07/2011) [5] http://www.essel.com.br/cursos (11/06/2011) [6] http://thekneeslider.com/archives/2010/04/17/5-axis-milling-machine-demonstrates-capabilities/ [7] http://www.machinery.co.uk/article/25325/micro-machining-.aspx [8] www.asianproducts.com/company/index.php?op=autoplay&cno=A10210750020244&item_id=P11 901826226356218 (20/08/2011) [9] http://www.milcowireedm.com/small$hole$edm.htm (19/04/2011) [10] http://www.portlaser.com/ (15/02/2011)

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