Abstract

According to the safety standards of machine tools, the operator of a machine tool has to be protected sufficiently against ejected parts and workpieces. During a turning process, the risk results mainly by rotating parts that comes loose completely or partially from the chuck or the workpiece. On the other hand, in milling processes, the hazard comes primarily from tools or fragments that rotate at high speed. A combined vertical turning on milling centers is possible in today´s tool machines, where both hazards can occur. From the technical safety point of view, this operation is not comparable to conventional turning due to the machine-side structure, the guard, the permissible workpiece size and the vertical position of the rotary axis. These results in new challenges, such as the selection of a suitable clamping system, the determination of the required clamping forces taking into account the process parameters and forces, the influence of the workpiece geometry on the mass moment of inertia of the workpiece or the workpiece energy to be considered in the clamped state. The deformation and movement behavior of clamping systems like three-jaw chucks and their components can be effectively determinate by means of numerical analysis and at the same time give conclusions regarding the safety. This Paper is based on the example of vertical turning on milling centers, as this so-called process integration creates new hazards due to workpiece clamping. For this purpose, the workpiece clamping of a cylindrical workpiece is simulated using an FE model. The interpretation of the results is focused on clamping and stability safety on the workpiece.

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