ShoPro Manual - MAL Manufacturing Automation Laboratories, Inc.
Contents
1. Figure 19 The top part shows the frequency spectrum of the hammer and the one under is accelerometer spectrum Hammer covers both natural frequencies H220_machine_hard mtb MalTF File Edt Measursment View Hels L Real Channel 1 er 1 5e 00 Real mAN le 00 5e 008 be 008 Frequency Hz X 1 000e 002 Y 1 639e 007 Imaginary Channel 1 5c 008 A Imaginary m N le 007 First natural frequency 588 Hz l l l l 500 1000 1500 2000 2500 3000 Frequency Hz X 1 000e 002 Y 1 174e 006 For Help press F1 l I l l 1000 1500 2000 2500 3000 Status E Data loaded A mr ear A ee ee fear an I I 3500 4000 4500 Dynamic flexibility of the machine at second natural frequency 2090 Hz l l l 3500 4000 4500 5000 SR 200kHz BW 5 0kHz FR 1Hz B O ea O Inbox Mic osof h GutPro Untitled W ShopPro Manual Microsoft Pewer PRD Q2 EO BO 2808 OA 520A Figure 20 Real top and Imaginary bottom parts of the measured Frequency Response Function It has two dominant modes at 588 Hz and 2090 Hz MAL 07 06 2006 MAL Inc User Manual for Shop Pro 18 STEP 3 STABILITY LOBE TORQUE POWER PREDICTION After the measurements are completed click on the Stability Lobes button Shop Pro will take a few seconds to do some calculations and then will display the stability lobes Any cutting condition above the curve will l2. READ EXISTING FRF FILE select Read Existing FRF File under Figure 12 Hammer accelerometer definition selection of frequency Measurement Method at the top of the range and the number of averages window there should be a checkmark beside it Next click Browse next to the Feed X Direction to find your FRF file for the feed direction If the feed and normal directions are not the same click Browse to find the FRF file for the Normal Y Direction UAL 07 06 2006 MAL Inc User Manual for Shop Pro s Shop Pro will calculate a suggested frequency range based on your setup but of course you can change it as long as it is within the range of the FRF files NOTE When opening an FRF file it is assumed that the measurements contained in the file are the same as the project units Once the file is opened the measurement values will be converted between Imperial and Metric units if the units are changed through Edit gt Preferences so it is important to choose the correct units for the project before opening the file DEFINE DYNAMIC PARAMETERS lf you happen to know the dynamic parameters of the machine tool you may select Define Dynamic Parameters under Measurement Method at the top of the Measurement Settings window there should be a checkmark beside it You will need to know the natural frequency damping ratio and modal stiffness for each of the major modes of the tool 4 000e 007 5 900e 00 2 250e
3. Solus WMI mN T ot 10 0 0004 ag Data leaded ak Hammer can not measure the natural frequencies 0 0002 beyond 2200 Hz 11 LNNT I I I e e a el Hl THN TAI TMI PAI AMI HHI AIM ARI HINI Frequency Hz Ri dte UA Y 4 r dle U0d Oulp edum Channel 1 This natural frequency is beyond the mamers excitation range Pi 500 4000 4500 ghid u 1000 1500 2000 eon 3 Trenquea mca lliz 2 et v 1 374e 004 For Help press FI SR 200kHz Bw O 0KHz FR THz Figure 18 Hammer spectrum must not drop to zero whenever you see peaks natural frequencies in the accelerometer spectrum Otherwise the measurement is not accurate MAL software indicates the poor measurement zone by indicating FRF Real and Imaginary parts with broken lines MAL 07 06 2006 MAL Inc User Manual for Shop Pro _17 H22xx_machine_hard mtb MalTF File Edt Measurement Yiew Hels Lok amp Q Q emer ir ve ei fr eo Input Spectrum Channel 1 0 0025 Hammer Spectrum 500 1000 1500 2000 2500 3000 Frequency Hz X 1 000e 002 Y 2 07Be 003 OutputSpectrum Channel 1 Natural Frequency 1 Acceloremeter Spectrum 500 2500 3000 Frequency Hz A 1 000e 002 Y 4 799e 005 For Help press F1 Status oe Data loaded Hammer does not drop to zero and covers both first and second natural frequency i ae a a l 3500 4000 4500 Natural Frequency 2 SR 200kHz BW 5 0kHz FR 1Hz
4. The National Instruments DAQ is used as an interface between the I O box and the computer allowing you to collect measurements Please follow these steps to install the DAQ Step 1 Remove Previously Installed Drivers Please first make sure that you have removed any previously installed NI DAQ drivers to avoid any potential conflicts To remove your drivers first right click on My Computer select Properties and then select the Hardware tab on the window that pops up Click al on the Device Manager button and you should see your Figure 1 DAQ card listed under Data Acquisition devices Select the Uninstall card and click on the Uninstall button button Next go to Start gt Settings gt Control Panel and then open Add or Remove Programs Find National Instruments Software in the list of programs and select it Click on the Remove button and follow the prompis Add or Remove Programs Currently installed programs FF Show updates Sort by Change or R _ E Remove amp J2S5E Runtime Environment 5 0 Update 6 145 00MB Programs A KSignAccessToolkit v1 0 Size 0 23MB gt if Launch Manager Size 1 42MB Add New af MATLAB 6 1 Torm M McAfee SecurityCenter ic McAfee VirusScan ens ea Microsoft Office XP Professional with FrontPage 215 00MB Add Remove Windows mozilla Firefox 1 5 0 4 Components E ie MyFirewall B i National Instruments Software Size Used Set Program Access and Last Used On ee To change this p
5. 008 Figure 13 Entering Dynamic Parameters for the Feed X Direction The dynamic parameters editor is similar to an Excel worksheet Click the button to add a new row Then click on one of the cells and type the value You can only add a new row with the plus button after the previous row has been completed The new row will be added to the top of the list but don t worry about the mode number because Shop Pro will automatically sort them from the smallest natural frequency to largest for the mode numbering lf the Feed and Normal directions are not the same there is an option to select a rigid direction which gives that direction some fixed parameters defined by us PREPARING THE HARDWARE The following describes how to set up the hardware for an impact hammer test Connect the signal conditioning box I O box to Data Acquisition card using the provided cable by National Instruments UAL 07 06 2006 MAL Inc User Manual for Shop Pro 13 Make sure that first two channels of the I O box are set to ICP Power On using the switch just above the BNC connection Connect the hammer to the first channel of the I O box with the BNC cable Connect the accelerometer to the second channel with the BNC cable Attach the accelerometer to the end of the cutter in x direction using wax or super glue You may need to clean the surface of the tool in order to make the attachments 4 CAUTION The accelerometer is a ve
6. Y 3 97 e 001 For Help press F1 Figure 17 You will see hammer impact force on the top and corresponding vibration measurements made from accelerometer at the bottom half of the window The shorter the hammer impact time duration is the higher the frequency range of the hammer will be Small hammers and hard tips give shorter impact duration higher frequency and large hammers and soft tips lower the frequency measurement range SR 200kHz BW 5 0kKHz FR 1Hz UAL 07 06 2006 MAL Inc User Manual for Shop Pro 16 Once the measurement is completed please check the Power Spectrum using SP button on the tool bar The power spectrum of the input top window the hammer must not drop to zero where there are natural frequencies which will be indicated by the peaks in the accelerometer bottom window Otherwise the measurement will not be able to cover the high frequency region where the hammer signal is close to zero Click on the real and imaginary box RI on the tool bar and look at the imaginary part The higher the peaks are weaker the machine is at that frequency where chatter may occur Rotate the cutter 90 degrees and repeat the measurement in the other direction if you did not click the FRF in Feed X and Normal Y direction are the same button during the measurement set up Heee too Wp Mal TF Ide dt ame SN 4 ee Fj A a core f T Channel Fir me ra Er eo Inpul Spectrum Channel 1
7. impact force applied on the cutter which is shown on the top and the oscillating signal on the bottom represents the vibrations measured with the accelerometer MAL 07 06 2006 MAL Inc User Manual for Shop Pro _15 Figure 16 Impact blows must be applied opposite to accelerometer The very first blow must be slightly stronger than the subsequent blows to set thresholds in DAQ card Light impacts are sufficient Excessive force may break the tool and damage the hammer Continue to hit until all the measurements are completed which will be announced by Shop Pro When the hammer bounces on the cutter Shop Pro will reject it by telling you that you had multiple or double hits The multiple hits occur when the cutter is slender and long hence flexible The cutter bounces back and touches the hammer before you can withdraw the hammer with your hand If you strike stronger than the very first impact you will saturate the data acquisition system and Shop Pro will reject it and ask you to strike lighter H22xx_machine_hard mtb MalTF File Edt Measursment View Held D Input time domain Status ee Data loaded Impact hammer force with almost 400 Newton amplitude and 0 4ms impact duration Force N 0 0002 0 0006 0 0008 Time s X 4 077e 005 Y 9 496e 001 Output time domain Channel 1 T t E e E F w 2 t oO a lt 600 i i 0 2 0 015 0 025 Time s x 0 000e 000
8. stot 10 00 f Error Codes 943 Data Mode Strip Chart Y Scale Mode Average Reading C One Shot C Auto Scale 0 019531 0 009766 0 014648 Continuous Full Range E Figure 9 Test Panels window of the Measurement amp Automation software If there is a green line running through the oscilloscope window it means your DAQ card is working properly Figure 10 DAQ Card Test window of Shop Pro For each channel check the voltage If the voltage stabilizes near 0 V after a few minutes that means the channel being tested works properly If the voltage stays very high check the cables and ICP power switches INSTALLING SHOP PRO Place the Shop Pro CD in your CD drive to automatically start the installer If the installer does not start automatically use My Computer to browse to your CD drive and open the file called ShopProV10 EXE Follow the on screen prompts to proceed with the installation UAL 07 06 2006 MAL Inc User Manual for Shop Pro STARTING SHOP PRO Insert the USB key and double click the Shop Pro icon A startup window will appear giving you the option to create a new project or open an existing one You must give your project a name and you can change the folder your project is saved in The startup window also gives the option of measuring with metric or imperial units After clicking OK on the startup window you will see the main program view with the Cutting Conditions menu open CALC
9. the noise and examining the hammer material and cutting conditions data we will try to guess what went wrong with your process After clicking OK Shop Doctor will present its findings to you STEP 3 INTERPRET THE RESULTS Once Shop Doctor has analyzed the data it will display the stability lobes calculated earlier with some extra information on it Shop Doctor will mark your current cutting condition which was input into the questionnaire with a red X so you may compare it to the stability zone Also if it could find a problem with your process it will display suggested cutting conditions marked with a green Below the stability lobes Shop Doctor will display a summary of Its findings UAL 07 06 2006 MAL Inc User Manual for Shop Pro _ 24 3 spb ShopPro File Edit Measurement View Diagnosis Help Le Shop Doctor Settings 3278 800 Chatter is detected at frequency 1077 Hz Try to cut at following cutting conditions 515 075 Optionl Option2 Option3 Option4 Spindle Speed rev min 8243 14580 5535 6567 Depth of Cut mm 2 00 2 00 2 00 0 88 Or select cutting parameters below on the dotted line in stability lobe Display Settings For Help press F1 SR 100kHz BW 5S OkHz FR 1Hz Figure 25 Shop Doctor Diagnostic s results Shop Doctor recommends you speeds and depth of cut alternatives to avoid problems you listed in the questionnaire Note that the diagnostics do not follow simple calculations I
10. wizard will open Select Install the software automatically and click Next The hardware should now be installed on your computer You can check if the device is working properly by ea right clicking on My SAG Batteries Computer and selecting Properties Then select the Hardware tab and z Disk drives click on the Device Display adapters Manager button The a DVD CD ROM drives DAQ card should be listed in Device Manager as seen in Figure 7 Device Manager ry Computer Data Acquisition Devices Figure 7 You should see your DAQ card listed in Device Manager lf you right click on the device and select Properties a window displaying the device properties will open Make sure that under Device Status it states This device is working properly Also make sure that the usage is set to Use this device enable in the drop down menu at the bottom of the window Step 4 Configure the Hardware Double click on the Measurement amp Automation icon on your desktop to open the configuration software Expand the Devices and Interfaces by clicking on the signs and your DAQ card should appear under either Traditional NI DAQ Devices DAQCard Al 16E 4 or NI DAQmx Devices see Figure 8 UAL 07 06 2006 MAL Inc User Manual for Shop Pro Base Right click on the name of the device and select Properties Click on the Al tab and ensure that the Polarity Range is 10 0V 10 0V and that the mode is
11. 1 T6 140 3 User Defined I Add New Chilled Cast Iron AL 6061 T6 95 HE Material AL 7050 T6 160 3 User Defined AL 7050 T6 150 Hardened Steel lt AL 7050 T7451 140 HB 3 z i Unat Gaeietart z AIPeahaam 14d Ff A AdAS bl Material t OZ Feed Direction ox Figure 11 Material selection and cutting conditions entry page of Shop Pro You can enter new materials or edit user defined material data NOTE You can change the material standard and thus the listing of materials by going to Edit gt Preferences and selecting the appropriate standard from the drop down menu Your preferences will be saved and will be used next time you start Shop Pro STEP 2 IMPACT HAMMER TESTS ON THE MACHINE TOOL The dynamic rigidity of the machine is measured via impact hammer tests To input the measurements you can chose to conduct a new impact hammer test select existing FRF measurements saved on your computer or input the dynamic parameters of the machine tool Please select one of these options from the top of the Measurement Settings form Most horizontal machining centers have a symmetric spindle which means that the stiffness and natural frequencies of the spindle are identical in the Feed X and Normal Y directions In this case check the FRF in Feed X and Normal Y are the same box and Shop Pro will ask you to make a measurement only in one direction X or Y which is up to you to decide The X direction i
12. AQ Legacy applications with Microsoft Visual C Thes feature will be installed on the local hard drive This feature and its selected subcomponents vail require 2 42 MB of disk space Figure 6 The Microsoft Visual Basic and Visual C Support features will be installed Click Next to continue the installation NOTE If you are using an older version NI DAQ driver software earlier than v8 0 the above procedure is similar but the graphics may not exactly match what you see If you are not sure which items to install you can simply select all the features under the Traditional NI DAQ 7 4 1 Legacy When the installer is finished select the Shut Down option to prepare for installing the hardware Step 3 Install the Hardware Device You can install the National Instruments PCMCIA device the DAQ card in any available Type II PC Card slot Complete the following steps to install the PCMCIA device UAL 07 06 2006 MAL Inc User Manual for Shop Pro 1 Remove the PCMCIA slot cover on your computer if any 2 Insert the bus connector of the device into the slot until the connector is firmly seated Never touch the exposed pins of connectors 4 CAUTION Please take precautions such as grounding yourself to prevent electrostatic damage to the device and its components 3 Attach the I O cable 4 Start your computer Windows should automatically detect the new hardware when it starts up and the Found New Hardware
13. MAL MANUFACTURING AUTOMATION LABORATORIES INC 2829 Highbury St Vancouver B C CANADA VE6R 3T7 http www malinc com Tel 604 228 9213 Fax 604 228 9269 Shop Pro Manual MAL Manufacturing Automation Laboratories Inc July 2006 INTRODUCTION shop Pro was designed to implement basic principles of advanced machining engineering of MAL s CUTPRO software at the shops by practicing machining process planners engineers and operators Shop Pro is not as detailed as CUTPRO which can accurately analyze machining operations with complex tools but it can rapidly allow users to benefit from the chatter stability lobe prediction feature of CUTPRO Shop Pro is a completely integrated one shot program that contains impact hammer test chatter stability torque power material removal prediction and machining diagnostics in seamless software Furthermore Shop Pro is equipped with an expert machining troubleshooter and advisory module Shop Doctor queries the problems experienced in the shop and uses the impact hammer measurements sound recording of the machining process and advises the user as to what might have gone wrong and how to overcome the vibration excessive tool wear and tolerance violations It takes only a few minutes to learn Shop Pro Please use the following quick guide before using the Shop Pro in practice UAL 07 06 2006 MAL Inc User Manual for Shop Pro INSTALLATION NATIONAL INSTRUMENTS DATA ACQUISITION DAQ
14. ULATIONS AND ANALYSIS STEP 1 WORK MATERIAL SELECTION AND CUTTING CONDITIONS INPUT Using the Cutting Conditions window click on one of the classes of materials You will see a sub class of materials on the right window where you can select the material that is closest to the one you will machine Shop Pro will scan its database and select the most accurate and closest material it has It can never exactly represent the material cutting force coefficient you have since it is dependent on the specific material tool geometry details and cutting conditions However the errors will be mostly within 30 in predicting chatter free depth of cuts but the stable speed pockets will hardly change In short you should give 30 room in selecting chatter free depth of cuts unless you calibrate the cutter in machining the specific material you are machining If you use solid end mills TI6Ale4V Al6061 Al7050 and Al7075 material databases will be accurate better than 80 since they were calibrated by MAL At the bottom of the page please select the radial immersion the number of teeth and feed rate The radial immersion is needed to calculate chatter free depth of cuts and speeds the feed is used to predict the torque and power See Figure 11 for a reference Once you click OK the program will take you to the next window Measurement Settings UAL 07 06 2006 MAL Inc User Manual for Shop Pro 10 Cutting Conditions Aluminum Alloy A AL 606
15. cquisition system You need to wait until the voltage level drops to close to zero the voltage offset is caused by the capacitors in the I O box You need to also make sure that there is a signal in the I O box This is automatically checked by the Shop Pro and if there is a problem a window will pop up asking you to check connections and wait for the voltage levels to drop and stabilize If the problem continues there is either a cable connection or driver problem You can check the status of the voltage levels by clicking the Test Panels button located in the top right area of the program The voltages should be relatively stable and close to 0 0 volts about 0 01 0 02 V is O K If the connections are correct and you are still experiencing problems you may restart the computer so that Windows can automatically detect the driver again A inik haps Ee Edt peireta Goan te hoi amp Awit eal ier ripe time demain GA lOi DW 5 Dihi FR ihi Figure 15 You will see FRF measurement window Click on Start button and begin delivering impact blows to the cutter Click the START button Give an impact on the cutter opposite to the accelerometer using your wrist as a pivot point when swinging the hammer Make sure that the first impact is slightly stronger than the following impacts since the first impact is used as a reference to check the maximum voltage set You will see two windows Half sine wave is the
16. ead to chatter vibrations Using the cursor you can select cutting conditions and Shop Pro will display torque power feed speed depth of cut and material removal rate for you Make sure that your machine has sufficient power and torque before you try a cutting condition on the machine You can change the Display Parameters as you wish to see selected regions of the cut torque and power curves 3 spb ShopPro Sees File Edit Measurement Yiew Diagnosis Help Osh Se 6 Stable Zone ShopPro Project Summary 0 094 Material Standard DIN nr Category Aluminum Alloy Material AL 6061 T6 Hardness Cutting Conditions 14950 Number Of Teeth 4 Diameter 20 00 mm Width of Cut 20 00 mm Side Offset 0 00 mm 2 288 Display Settings For Help press F1 SR 100kHz2 BW 5 0kHz FR 1Hz Figure 21 Stability lobe shows chatter red and stable green zones Cursor location automatically calculates speed depth feed material removal rate torque and power on the right tool bar You need to be aware of several facts in chatter stability prediction which may not match the cutting tests exactly There are four important inputs to the theory Material cutting coefficient which changes about 20 25 with the insert geometry and even more if the cutting edge has a radius and the feed is less than the edge radius UAL 07 06 2006 MAL Inc User Manual for Shop Pro MAL _19 Also aS mentioned in the hammer tes
17. g you need to first record an air cutting to record the background noise of the spindle Start the spindle and push the start button to record the air cutting For separated recording it will record for only for 2 seconds and then switch to metal cutting Once you start metal cutting and hear vibration noise click the Start button to record the sound Recording will take only a few seconds please try to capture the sound during problematic part of the machining process It may be best to try a straight line cutting test at a given speed and axial depth of cut Shop Doctor borrows the feed radial depth of cut cutter and hammer information from the previous pages UAL 07 06 2006 MAL Inc User Manual for Shop Pro oe 00 spb ShopPro File Edit Measurement View Diagnosis Help D coe el amp 2 Ba A A acl Mds se foc FE Be Sound Settings For Help press F1 DAQ Card DAQCard AI 16E 4 SR 100kHz BW 5 0kHz FR 1Hz Figure 23 Sound recording page First you need to record air cutting followed by recording the noise generated during metal cutting Once you have your separate Air and Metal Cutting sounds you me may play them to make sure you have the right selections by clicking on the on the Air and Metal Cutting Play buttons located on the top bar Other buttons on the top bar allow you to switch E between views of various representations of the sound data Duon collected You may export
18. gure 0 00 Bytes of disk space Directory for Traditional NI DAQ 741 Legacy D Program FilesWMational Intruments NEADS Browse Browse Figure 3 Installing the NI DAQ driver software Expand Traditional NI DAQ 7 4 1 Legacy by clicking the sign You can now see the list of available features to install Select NI DAQ OPC Server from the list and select Install this feature to a local drive MAL 07 06 2006 MAL Inc User Manual for Shop Pro lt National Instruments Device Drivers Movember 005 Features NATIONAL Select the features bo install eINSTRUMENTS 55 Data Acquisition Support of OLE for Process Control Go NI 5 0 B E Traditional NI DAG 7 4 1 Legac LabVIEW 8 0 Support LabVIEW 7 1 Support LabVIEW 7 0 Support LabVIEW RealTime Sup x LabWindows Lvl Suppo NI DAQ OPC Server This feature will not be installed Install this Feature to a local drive Install this feature and its subfeatures bo a local drive E te ad cfc De mot install this Feature sted subcomponents vaill Pl obton benroce cern aaee Sn SACE Real Time and Embedded Industrial Communications D Program Files WW ational Inetuments s MI DALS Brows ree Ss aaa ee es es Se ee aaa Figure 4 Selecting install for the NI DAQ OPC Server National Instruments Device Drivers Movember 7005 Features IONAL Select the features to install INSTRUMENTS 9 Data Acquisition Support of OLE fo
19. ment conditions for a live cutting test UAL 07 06 2006 MAL Inc User Manual for Shop Pro _2 1 Hardware Notes The microphone that is included with Shop Pro has a built in pre amp so it can record directly to the computer s sound card without any other hardware The procedure for this setup is as follows Connect the XLR to RCA adaptor to the bottom of the microphone Plug the end of the adapter into the red input of the RCA to Stereo Jack cable Insert the Stereo Jack pin from the cable into the microphone input of your sound card select Sound Card as the Sound Recording Device from the drop down menu on the Sound Settings form The microphone can also record through the I O box The procedure for this setup is as follows Make sure that the ICP power is off on the channel where you will be inserting the microphone Connect one end of the XLR cable to the microphone and the other end to the XLR to RCA adaptor Connect the RCA to BNC adaptor to the XLR to RCA adaptor Connect the RCA to BNC adaptor to the desired channel on the I O box Shop Pro assumes Channel 0 by default select DAQ Card as the Sound Recording Device from the drop down menu on the Sound Settings form lf you are recording sound you can choose between a combined recording where you only record sound once and select the air and metal cutting sections from the graph or two separate recordings one to record air cutting and the other to record metal cuttin
20. n Shop Pro does not coincide with the machine s x axis but the feed direction in the NC program In most cases as long as the impact measurements are collected in UAL 07 06 2006 MAL Inc User Manual for Shop Pro a the X and Y directions the program s predictions are not influenced too much by the feed direction IMPACT TEST First select Impact Test under the Measurement Method at the top of the window there should be a checkmark beside it When you first use Shop Pro please enter the hammer and accelerometer model numbers and calibration factors supplied by the manufacturers This needs to be done only once whenever you buy a new sensor set Hammers and accelerometers come with factory set calibration factors that are indicated in their documentation Once you have entered the hammer set data you can simply select it from the dialogue box You will want to set the Number of Averages number of impacts to at least 5 For more accurate measurements you may wish to take about 10 or more measurements Shop Pro will calculate a suggested n frequency range based on your setup del Dytran 560004 however you may change it as you see fit wW The Advanced button allows you to Sour change the Sampling Rate and oytran 322571 l Frequency Resolution for the test based F on your DAQ hardware NOTE After a hammer test you can export the transfer function data to a FRF file by selecting File gt Export gt FRF Data
21. r Process Control H NI DAGQme 8 0 ES Traditional NI DAG 7 4 1 Legac LabVIEW 8 0 Support LabVIEW 7 1 Suppo LabVIEW 7 0 Support i LabVIEW Real Time Sup ea gt LabWindows CVI Suppo NI DAQ OPC Server This feature will be installed on the local hard drive Microsoft Visual Basic Su Microsoft Visual C Suppo Instrument Control Modular Instruments Th s feature and its selected subcomponents will Motion and Vision require 2 15 MB of disk space Real Time and Embedded Industrial Communications eR Be Ge H E E el E A Directory for NI DAQ OPC Server D Program Files National Instruments NIDAD Browes Figure 5 The NI DAQ OPC Server feature will be installed UAL 07 06 2006 MAL Inc User Manual for Shop Pro _5 similarly install Microsoft Visual Basic Support and Microsoft Visual C Support BE National Instruments Device Drivers November 7005 Features Select the features bo install a Data Acquisition 9 NI DAGm 8 0 LabVIEW 7 0 Support e LabVIEW Real Time Sup LabWindows CY Suppo NI DAQ OPC Server Microsoft Visual Basic Su Microsoft Visual C Suppo Instume Aral ts e Modular Instruments Moton and Vision RealTime and Embedded Industrial Communications m E HH E Ee lt i Directory for Microsoft Visual C Support D Program Files Mational Instruments NI DADY NATIONAL INSTRUMENTS Files used to create Traditional NI D
22. rogram or remove it from your computer dick Change or Remove ey g Nero 6 Ultra Edition Size fe PowerProducer Size R Drive Image remove only jE Realtek AC 97 Audio A Sentinel System Driver 5 42 0 32 bit Figure 2 Click Remove to uninstall the National Instruments Software UAL 07 06 2006 MAL Inc User Manual for Shop Pro Step 2 Install Driver Software Insert the NI DAQ CD into your CD drive and the installer should open automatically If it does not open you can open the installer manually by double clicking on the My Computer icon on your desktop browsing to your CD drive and opening the file setup exe NOTE Do not insert the DAQ card into your computer until you have installed the drivers Windows may not detect the device and you might see warnings asking you to install the driver In the opened window you can see the Traditional NI DAQ 7 4 1 Legacy option is unselected in the default installation settings a National Instruments Device Drivers November 20059 Features NATIONAL Select the features to metall INSTRUMENTS Sq Data Acquisition Traditional NI DAQ Legacy has the same lo Se NI DAG rin 8 m Vis tunctions and works the same as NI DAG 6 9 x Di but ig updated so you can use Traditional NI DAQ s Legacy and NI DAQms in the same computer X This feature will not be installed This feature and its selected subcomponents will re
23. ry sensitive device that can be damaged easily We recommend using dough or paper tape to hold the cable on a stationary part of the spindle housing to avoid cable entanglements and to catch the accelerometer if the adhesive fails Taping the cable has the added advantage of removing the tension from the cable acting on the sensor which reduces the accuracy of measurements The accelerometer is best located between the cavities of the helical flutes or on the smooth cylindrical surface of the indexed cutter body You need to apply light impact blows on the cutter but exactly on the opposite side of the accelerometer Tool Accelorometer impact hammer Workpiece AR EE Shop Pro 4 1072 REAL PART OF TF 7 oe IMA A DAQ Card MAL Signal conditioner I O box Figure 14 Impact hammer set up The hammer is connected to the first Channel 0 and the accelerometer is connected to the second channel Channel 1 of the I O box The I O box is connected to the Data Acquisition Card Now you are ready to make the impact measurements which is the most important step in predicting chatter vibration free soeeds and depths of cuts UAL 07 06 2006 MAL Inc User Manual for Shop Pro 14 PROCEDURE TO MAKE IMPACT TESTS As soon as you push the OK button on the measurement set up a measurement window will pop up Make sure that the ICP power is on If the system is just powered or the cable just connected there may be a large offset in the data a
24. s that the information gathered from the hammer test material data cutter geometry depth and width of cut feed sound data recorded during machining test and the user s query give us some hints about the possible sources of machining problems experienced in an operation Shop Doctor does its best to guess using a Fuzzy Logic based system equipped with our expertise However we are not near the machine and many other things might have influenced the operation beyond our control Please use it with caution and if it solves your problem you are lucky Otherwise sorry there is not always an easy solution to the problems in the shop Steps to run Shop Doctor STEP 1 START SHOP DOCTOR Click on the Shop Doctor icon in the lower left corner of the program and the following window will pop up giving you the option of either recording new sound data during machining or using a previously recorded existing sound file Shop Pro supports Shop Pro sound files msd and Windows audio files wav for opening and exporting You may record sound either through your computer s sound card or through an I O box Clicking the Sound Measurement Settings button will allow you to change the sampling rate the frequency range for the sound recording and the channel for recording changing the channel is only applicable if you are using the I O box Sound Settings Sound Measurement Settings Cancel Figure 22 Setting the sound measure
25. set to Differential X DAQCard Al 16E 4 Device 1 Measurement amp Automation Explorer Contiguration E Properties FalDelete YA Test Panels Attribute Value Description i l The NI DAQ device number fa coe and Interfaces Pocket l The PCCard socket that this device is in A Traditional NI DAQ Devices P Serial Number 0xCE1116 The serial number of the device BA DAQCard Al 16E 4 Device 1 Ba NI DaOme Devices Configuring Device 1 DAQCard Al 16 4 PRE PSI System Unidentified y Ports Serial amp Parallel as Scales Select the default f Software aa aes analog input al edad achat settings for the ima IVI Drivers pases GJ Data Neighborhood Sustem l Accessory OPC Remote Access Remote Systems Differential Cancel ppl Figure 8 Hardware configuration in Measurement amp Automation You may check the status of your measurement instruments by right clicking on the DAQ device and selecting Test Panels however this function is also available in a friendlier user interface in Shop Pro see Figure 9 and Figure 10 below UAL 07 06 2006 MAL Inc User Manual for Shop Pro Test Panel NATIONAL Device Name Device Number INSTRUMENTS PCIMIO 16E 4 a Analog Input Analog Output Counter 1 0 Digital 1 0 DAQ Card Test Channel 1000 0 zal Input Limits High 10 0000 Last Error Low 10 0000 0 00 r 0 Fatal fioon0 Error az
26. t you may not be able to measure the machine accurately especially if the natural frequency is high The machine may seem to be more flexible than it is and you may be able to cut deeper than the stability lobe indicates The dynamic stiffness of the spindle may change at speeds higher than 10 000 rom due to each spindle s preload mechanism The preload shifts the natural frequency from the impact test measurements that are collected when the spindle is at rest In that case measure the chatter noise with the sound card that is available in the Shop Doctor and shift the stability lobes to the right or left to adjust the frequency changes When the spindle speed is low the machine may cut a lot deeper than the Stability lobe indicates This phenomenon is called Process Damping which is due to friction between the tool s flank and many waves left behind the insert The friction acts as a damping mechanism in the process and chatter is reduced but at the expense of faster tool wear If you grind the cutting edge slightly or create few micron of zero clearance angle you will increase the process damping decrease the chatter hence increase the depth of cut at low speeds However you will draw more power and torque from the machine 07 06 2006 MAL Inc User Manual for Shop Pro _20 SHOP DOCTOR TROUBLESHOOTING MACHINING OPERATION shop Pro has an expert machining diagnostics module that needs to be used with caution It assume
27. t is based on an embedded expert system powered by a Fuzzy Logic engine whose rules can be changed only by us We think we know something about machining processes and how to diagnose a problem based on everything we recorded and heard about the process and the machine If we are wrong please write to us to upgrade our expert system logic UAL 07 06 2006 MAL Inc User Manual for Shop Pro
28. your recorded sound into either a wav or msd sound file by selecting an option from the drop down menu of the Save Sound Data button located in the bottom right corner of the screen or by clicking File gt Export gt Sound Data and choosing the appropriate options STEP 2 QUERY ABOUT YOUR MACHINING PROBLEM After recording and pushing the Diagnosis button Shop Pro will display the following window and ask you to specify spindle speed and depth of cut during the diagnostics cutting test UAL 07 06 2006 MAL Inc User Manual for Shop Pro Questionnaire Cutting Conditions Spindle Speed rev min Depth Of Cut mm Feed Fate Machine Characteristics Maximum Spindle Speed rev min 15000 Do you hear high pitch noise during machining e Wes C Not sure Do you get rough surface finish with vibration marks g Not sure Do you see uneven tool wear on each tooth Yes C Not sure The surface finish is good but there is overfundercut which violates the part tolerance E Yes Cancel Figure 24 Questionnaire about the symptoms of your machining problem The first question is about the noise If the process chatters you will hear a high pitch irritating noise The rough wavy surface finish may be due to chatter or poor cutting speed selection The uneven tool wear may be caused by tool setting errors and the last question is related to tolerance violations caused by incorrect speed selection By listening to
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