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Machine Tools and Machining Systems Evolution

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 the last 50 years have a large influence on manufacturing
systems. Achievements and development of computer and
information technologies, progress and advancements of
numerical controls and development computer aided
(CAx) systems are contribute to: increase of the
productivity of machining processes, products quality and
development of new machine tools.
To this day is to accept some basic conception of new
machining systems, which are result of turbulent market.
In this paper is presented of the some main trends in the
development of machine tools and parallel kinematic
structures (Stewart, 1960-65) as like basis for
development of new generation of machine tools,
reconfigurable technological systems and reconfigurable
machine tools what are the main basis for development of
MACHINE TOOLS AND MACHINING new machining systems.
SYSTEMS EVOLUTION
Milan JURKOVIĆ
Zoran JURKOVIĆ

Abstract: Evolution of machine tools and machining

systems is a process of continuous inovation and
advancement of existing technologies, machining systems
and the survival of numerous technical systems depend on
the efficiency of their application. Today, in world exist
completely new trends in build up the machine tools and
the machining systems. Numerous demands of the market
for increasing precision of the machined surfaces and
products assortment require the development of adequate
machining systems. The review of some conception of new
machines and machining systems is given here, based on
Stewart parallel mechanism. In this paper, the review of
some main trends in the development of machine tools,
intelligent machining systems, reconfigurable machines
and machining systems is given.
Fig. 1. Development-evolution of machine tools and
Key words: machine tools, development, parallel machining systems
kinematics, high speed machine, reconfigurable systems

2. EVOLUTION EPOCH IN THE

1. INTRODUCTION DEVELOPMENT OF MACHINE TOOLS

Modernization and development of machine tools are a The old epoch in the development of machines and
process of continuous inovation and advancement of machining systems:
existing technologies, machining processes and
 1700-1870 Pre-automatic cutting machines epoch -
machining systems. A general trend as regards the growth
handling control of cutting machines epoch.
of production in this technological developed world is
more and more based on modernization and application of  1870-1900 Automatic cutting machines epoch.
modern machining systems and new technologies, The new epoch - automatization and knowledge:
flexible automatization, computer-integrated production,
what is the main aim to achieve a higher-quality, cheaper  1900-1955 Rigid automatization epoch and pre-
and faster production. Modern concept of the machine computer-numerical control (CNC) epoch.
tools design are characterized by development: machine  1955-1990 NC and CNC automatization epoch (1952
tool modules, intelligent and integrated manufacturing first NC machine, 1958 first machining centre and
systems, reconfigurable machines and systems, parallel 1960 Chicago Fair (90 models of NC machines).
kinematic mechanism of machine tools and high speed
 1990-2005 Knowledge epoch. Parallel kinematic
machines [1-13].
mechanism of machine tools /Parallel kinematic
The machine tools from first lathe by 1717 years
machines, high speed machines.
(England) and drilling machine by 1774 years (England)
have almost build up with similar concept for 250 years  2005-2008 today: Intelligent and integrated machining
(Fig.1) [2,3,4]. Development of science and technology in systems, Rapid prototyping epoch.

329
The nearer future (up to 2020) - new machine:
 Reconfigurable machines, reconfigurable machining
systems, intelligent control, intelligent manufacturing b)
and intelligent factories epoch.

3. GENERAL MODEL OF STEWART

MECHANISM
a)
c)
Stewart mechanism has six degrees-of-freedom (Fig. 2 ).
The upper plate is direct connected to spherical and lower
plate with universal joint. On upper plate are mounted
end-effectors and on lower plate worktable, chuck Fig. 4. Some configurations of model Stewart platform
[14,15].

platform

base

spherical joint
universal joint

Fig. 2. Main model of Stewart mechanism

Fig. 5. The six degree-of-freedom Stewart platform
Because of relatively large flexibility a wide application
of this mechanism is from simulation flying to industrial Application of Stewart mechanism is natural for robots,
robot and machine tool. Stewart mechanism has more while it is inaugurate to new approach in making
variants depends on numbers path, type and arrangement machining centers and machine tools after more than 100
of joints, type drive and numbers of freedom degrees years of traditional machine tools designed.
(Fig.3 & Fig.4).
4. PARALLEL KINEMATIC MACHINE
TOOLS DEVELOPMENT
First solution of Stewart platform
n=8
g=9 Model machine tools based on Stewart mechanism have
f1 = 3×3+3×1+3×2 = 18 the following characteristic:
F = 6× (n-g-1) + f1 = 6×(8-9-1) +18 = 6
 in base and platform are openings for joint,
simmetrical and asymmetrical,
The most famous configuration of  in base are auxiliary openings for fit (mounting ) of
Stewart platform components and clamping of workpieces,
n = 14
g = 18  on platform is opening for main motion transmission
f1 = 6×3+6×1+6×2 = 36 or end-effector,
F = 6×(n-g-1) + f1 = 6×(14-18-1) +36 = 6
 on platform is model biaxial-head, so that model have
8 degrees of freedom motion,
Stewart platform with 12 degree of
freedom
 joint links possibility different configurations of
n = 14 combining spherical and universal joint.
g = 18
f1 = 6×3+6×1+6×3 = 42
During the 50 years, machine tools have designed and
F = 6×(n-g-1) + f1= 6×(14-18-1) +42=12 developed basis on conventional methods and
improvement of existing technical decisions at machine
tools (design form, drive, control, transmission
Fig. 3. Degrees-of-freedom for some configuration of mechanism, etc.).
Stewart mechanism The most marked changes are realized in control system
(NC, CNC, DNC, AC, FMS). Rapid development of NC
The mechanism has applied by fast robots for assembly and CNC has influenced on new approach in designed
and second special function as micro-macro robots, modern high speed machining tools, industrial robots and
machine tools and machining centers (Fig. 5)[16]. flexible machining systems with parallel kinematic

330
mechanism. Parallel Stewart mechanism has characteristic and a requirement of six actuators for a five degee-of-
that structure and actuators to take effect parallel, what is freedom task (milling, drilling and similar operations).
a contrary to traditional machines (Fig. 6 and Fig. 7). There are also machines which combine parallel and
serial kinematics in their configuration called hybrid
kinematics.
Research and development efforts, in field of parallel
kinematic machines, at organizations around the world are
addressing the following issues [13]:
 optimization work volume,
 improved part programming,
 improved control capabilities,
 improved modularity,
 improved cost/performance ratio, etc.

5. THE MAIN TRENDS IN THE

DEVELOPMENT OF MACHINE TOOLS

The modern machining systems are based on the

application of flexible technology in all phases of the
machining process. The main trends in the development
of machine tools are:
 high speed machine tools,
 structure materials,
 parallel kinematic machine tools,
 hybrid machine tools,
 machines for micromachining,
 reconfigurable manufacturing systems,
 reconfigurable machine tools.
Fig. 6. Parallel kinematic machines (Tricept)
5.1. High speed cutting machines
Since commercial launch at the 1994 IMTS in Chicago, Although, German research Carl Salamon was carried out
these machines will not generally replace the the first investigations of applying high speed cutting: 440
conventional machines, although, this concept offer m/min for steel, 1600 m/min for bronze, 2840 m/min for
manufactures a number of advantages: higher structural copper and aluminium up to 16500 m/min still 1931, for
rigidity, higher force capacity, lower moving mass and commercial use need to wait a half century.
mechanical and frame simplicity which was reflected to High speed cutting (HSC) machines in recent 30 years has
lower weight required for high dynamics. been mostly researched from the following aspects:
 motor spindle designs (mounting, bearings, high
frequency up to 100 000 rpm, stiffness),
hexapod legs with
servoengine
 high dynamic feed drives (linear motors),
 framework and kinematic structure designs,
joining rods  fast CNC control.
For industry application are developed 5 axes CNC
oktaedar holder milling machines and high speed turn-milling machines
(die&mold, aircraft industry), Fig. 8. Some advantages of
HSC machines are:
spindle engine  reduction machining time,
 reduction of planning and manufacturing costs,
spindle holder  reduction cutting force,
 improved of work surface quality,
workspace  hard-to-machine materials, etc. [11,17].
workpieces pallet 5.2. Structure materials
High measurement accuracy and precision is reached
through the extreme rigidity. Structures have traditionally
been made of iron, and the current tendency is to use
Fig. 7. New concept of high speed machines improved, toughened iron. For small batches of machine
welded steel can also be used. Besides, machine
Some of disadvantages include: complex work volume, foundation frame can be make by concrete polymer
limited orientation range of motion, straightness errors composite, instead of the usual sheet metal or castings.

331
High speed requires that moving parts be light but that a Intelligent control methods are: artificial intelligence and
reasonable stiffness level be maintained. computational intelligence.

Automatization
Intelligent system
Manual

Intelligent Machining systems with Flexible Classical

machining systems artifical intelligence machining systems machining systems
0% 25%
25%

50% 50%
75%
100% 75%

Fig. 9. Degree of machining systems automatization

Intelligent control based on artificial intelligence:

 Expert or Knowledge-Based Control.
 Qualitative Reasoning Control.
 Fuzzy Control.
Intelligent control based on computational intelligence:
 Neural Network.
 Evolutionary Algorithms.
Fig. 8. Machining center Okuma PM – 600 with parallel  Adaptive Control.
kinematic (30000 min-1, 7,5 kW)
CONVENTIONAL
CAD/CAM SYSTEM
Cast iron is therefore replaced by aluminium or welded
steel. Aluminium is lighter, thus permitting massive
NN LEARNING CAD MODEL
material without the weight penalty. Welded steel enables MODULE OF THE PART
USER
thinner walls to be used, but the manufacturing technique
for manufacturing closed parts is time-consuming and NN DEVICE MANUAL INPUT

expensive. INTERNAL INTERFACE DECODING

More sophisticated materials such as carbon fibre ADAPTABLE
CONTROL
composites have been used in some applications, though
mainly for research. Composite structures are expected to POSITION FUNCTION

be used widely in the future for high speed application MEMORY

X, Y, Z
MEMORY
M, S, T W M

[18].
INTERPOLATION
FUNCTION PROGRAM
5.3. Hybrid machine tools PROGRAM

Hybrid processes i.e. combination (integration) of

COMPARISION POSITION MEASURING
processes have for main goal increasing productivity
which is not possible in single process (laser aided milling
AMPLIFIER
and turning), and/or machining difficult materials.

5.4. Machines for micromachining Fig. 10. CNC control unit based on NN [5,19]
From day to day production trends of micro- and
nanometre size parts increasing (electronics, 7. NEW MACHINING SYSTEMS
biotechnology, optics, etc.). These trends have reflection
On account of the fast market changes and the market
on machine tools design (smaller but more accurate
demands for new products it is necessary to conduct a
machines with high spindle speed, without friction and
research of the new manufacturing systems and
offset capable).
technologies to satisfied the markets demands. However,
the flexible manufacturing systems are reaching their
6. INTELLIGENT MACHINING SYSTEMS prime in the industry, manifesting the need for new
manufacturing systems such as reconfigurable
Intelligent machining and manufacturing systems manufacturing systems (RMS) [3,7,8]. Reconfigurable
integrate technologies related to sensing, modeling, machine tools (RMT), are new type of machines
control and monitoring. Fig. 9. shows degree of modularity with modification of structure hardware with
automatization the some machining systems [6]. the goal to increase flexibility. The improvements

332
obtained from the reconfigurable manufacturing system 8. CONCLUSION
possess the following characteristics (reconfiguration
cost-RC and reconfiguration time-RT): On account of the fast market changes and the market
 Modularity: components are modular (RT). demands for new products it is necessary to conduct a
 Integrability: interfaces for integration (RC & RT). research of the new manufacturing systems and
 Customization: flexibility limited to part family (RC). technologies to satisfied the markets demands. However,
 Scalability: capacity can be easily changed (RC & the flexible manufacturing systems are reaching their
RT). prime in the industry, manifesting the need for new
 Convertibility: functionality can be easily changed manufacturing systems such as reconfigurable
(RC & RT). manufacturing systems. The future development of
 Diagnosability: systematic embedded diagnostics (RC machine tools and machining systems will be incremental
& RT). and less radical. Above mentioned trends in machine tools
development will be provide advanced manufacturing,
manufacturing for new millennium with demands for the
Reconfigurable higher accuracy (Fig. 13) [21].
Functionality Manufacturing
Transfer Line

System

normal machining
High

100
µm
Turning
Production Volume

Special Milling
10
System Grinding

Machining accuracy
Lapping HSC
Capacity Honing
1
Flexible Manufacturing precision machining
Medium

System Special grinding

0,1
FM
Ultra precision
Cell
manufacturing
0,01
Low

NC machine Ion beam

ultra precision machining
machining
0,001
Low Medium High
Part Numbers per System (Variety) Molecular
manipulation
High Retool Costs
1950 1975 2000 2025 year
High Initial Capital Costs
Fig. 13. Developments of accuracy
Fig. 11. Review types of manufacturing systems and
reconfigurable machine tools In the near future, we can expect rapid development and
implementation of reconfigurable manufacturing systems
7.1. Reconfigurable machining systems that will be able to satisfy market demands.

Reconfigurable machining systems (RMS) are systems of

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