Technical University of Cluj-Napoca

Faculty of Machine Building

Department: Engineering Design and Robotics
Academic Discipline: Machine-Tools, Manufacturing Equipment and
Logistics

PROJECT YEAR

Design a Disk Type

Tool Magazine for a CNC Machine

Student: Lăcătuș Iustina

Specialization: RI English Class
3rd License Year
Group: 1533/1

Academic Year Project Coordinator,

2019 – 2020 Professor Eng. Bogdan Mocan

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 Contents:
1.Technical memo...............................................................................................4

1.1. Theoretical considerations...........................................................................4

1.2. Disk tool magazine – Concept......................................................................5

1.3. Functional features imposed and Objectives................................................6

1.4. Main components and operating principle...................................................7

1.5. 2D Drawing Disk Type Tool Magazine for a CNC Machine.............................8

2. Computational calculation memo...................................................................9

2.1. Motor selection............................................................................................9

2.2. Drive mechanism.......................................................................................17

2.3. Bearings selection .....................................................................................22

2.4. Tool holders and pockets............................................................................24

2.5. Sensors selection .......................................................................................26

2.6. Assembly drawing…...................................................................................27

2.7. Conclusions….............................................................................................28

3. Bill of materials…..........................................................................................29

4. Annexes….....................................................................................................45

5.Bibliography………………………………………………………………….…………………………….46

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Disk Type Tool Magazine

FIGURE 1- 3D VIEW OF THE DISK TYPE TOOL MAGAZINE

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 1.Technical memo
1.1. Theoretical considerations:

An Automatic tool changer or ATC (Figure 1) is used in computerized numerical

control (CNC) machine tools to improve the production and tool carrying capacity of the machine.
ATC changes the tool very quickly, reducing the non-productive time. Generally, it is used to
improve the capacity of the machine to work with a number of tools. It is also used to change worn
out or broken tools. It is one more step towards complete automation.
Tool magazines are generally employed in CNC drilling and milling machines. Compared
to tool turrets the tool magazines can hold much number of tools therefore proper management of
tools is essential. Duplication of the tools is possible and a new tool of same type may be selected
when a particular tool is worn off. The power required to move the tools in a tool magazine is more
in comparison with that required in tool turrets. The following are some of the tool magazines used
in automation.

Depending on the shape of the magazine, ATC can be of two types:

 Disk (or drum) Type changers are used when the number of tools is lower than 30.
The tools are stored on the periphery of the drum. (Figure 2).
 Chain type changers are used when the number of tools is higher than 30. (Figure 3).

FIGURE 2- DISK TYPE MAGAZINE

FIGURE 3- CHAIN TYPE MAGAZINE

Source: https://en.wikipedia.org/wiki/Automatic_tool_changer

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 1.2. Disk tool magazine – Concept

I was looking for similar drum/disk type magazines of famous brands such as Haas ( Figure
4) which are also the inspiration for my following concept. This version of tool magazine suits the
best for the functional features imposed presented earlier.

This Haas-designed and built 30+1 side-

mount tool changer holds 30 tools, plus
one in the spindle, to increase
productivity and reduce setup times. A
high-speed double-arm gripper swaps
tools quickly to minimize non-cutting
time. Locating the tool changer outside
of the work envelope frees up additional
workspace, keeps tools and tool pockets
free of contamination, and adds greater
flexibility when using large fixtures or
rotary tables. With adjacent pockets
empty, the tool changer will accept
oversize tooling, and there’s a built-in
automatic recovery process, should a
tool change be interrupted for any
reason.

FIGURE 4- HAAS CONCEPT MAGAZINE

 HSK-A63 taper
 Fast tool changes shorten cycle times on every tool change
 Pocket Tool Table in the control allows complete control over the tool changer
 Identify tools as LARGE to leave adjacent pockets empty
 Identify tools as HEAVY to slow tool changer motion

Source: https://www.haascnc.com/productivity/tool-changer/smtc-30-hsk-hs.html

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 1.3. Functional features imposed and Objectives:

Designing an automatic tool magazine with the following data:

The magazine specifications

Tool capacity 30T

Type Disk Type Tool Magazine
Number of tools 30
Tool Models ISO/ATC/CAT/BT
Tool Rotation 2 sec
Time/Positioning time
Maximum Tool Weight 7 kg
Maximum Load 210 kg
Motor Type Servo-motor
Worm Gearbox

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 1.4. Main components and operating principle
The main components of disk tool magazines are the following:
 Magazine frame  Worm gearbox
 Tool pot (pockets)  Sensors
 Belt Pulley Drive Mechanism  Ball bearings
 Servo-motor  Tool holders
 Pneumatic Motor

Magazine frame - specifically designed for all kind of CNC. Tool pot is made out of
engineering plastic resulting in a low weight. Pulley - for transmission of the motion on the belt
(we have a belt-pulley drive mechanism). Gearmotor: is used because that moves the pulley’s belt.
A gearmotor is a homogeneous and compact unit consisting of a gear unit and a motor. In electrical
drive technology as produced by SEW-EURODRIVE, it is also always an electric motor. The idea
of a "motor-gear unit aggregate" can be traced back to a patent from the Bruchsal-based design
engineer and entrepreneur Albert Obermoser in 1928: He invented the "Vorlegemotor" (geared
motor).
Since then, the gearmotor has been developed further and further and new types of gear
unit have been invented. In terms of motors, direct current technology has become less important,
therefore gear units are nowadays most often combined with AC motors or servomotors. Worm
gearbox- is preferred because is the most compact type of system and is useful when space is
limited. Worm gears are used when there is needed great reduction speed and great torque increase.
Sensors: are used for the correct positioning of the tools in the right place so the exchange can be
performed.

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1.5. 2D Drawing Disk Type Tool Magazine for a CNC Machine

FIGURE 5 - 2D DRAWING OF THE M AGAZINE WITH OVERALL DIMENSIONS

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 2. Computational calculation memo
2.1. Motors selection:

I used Oriental Motor’s motor design engine based on web at:

http://www.orientalmotor.com/motor-sizing/ .The input values are related to the 3D model and the
theoretical dimensions for this concept, and they include table diameter, thickness, mass, number
of tools, tool mass/mass load, drive shaft dimensions, transmission type.
The motor I chose is a servo-motor with Gearbox Integrated (Figures 5,6,7, and 8)
because of its high intermittent torque, high torque to inertia ratio and its good control of velocity
and they are generally used as a high-performance alternative to the stepper motor. It was
calculated using a motor sizing tool from the company “Oriental motor” using the data from the
model.The servo-gearmotor power resulting from the calculations is:

T ⸱ 𝑉𝑚 [rad/s] = 278,4 ⸱ 0,57 ≅ 158.688 W (Annexes)=> Servo-motor

FIGURE 6- SERVO MOTOR WITH GEARBOX INTEGRATED

The key features of a servo gearmotors or servo-motor with Gearbox Integrated are Power,
speed, and precision. Also, the modular system is the key to unlocking extensive combination
options and makes the most diverse variety of gear unit and motor constellations in this field
possible.

Source: https://www.sew-eurodrive.de/products/gearmotors/gearmotors.html

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FIGURE 7- 3D VIEW OF THE SERVO -MOTOR WITH GEARBOX INTEGRATED

FIGURE 8- 3D VIEW OF THE SERVO -MOTOR WITH GEARBOX INTEGRATED

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FIGURE 9- 3D VIEW FROM THE BACK AND THE CONNECTION OF THE MOTOR WITH BELT PULLEY DRIVE MECHANISM

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FIGURE 10- 3D VIEW OF THE MOTOR WITH BELT PULLEY DRIVE MECHANISM

FIGURE 11- CONNECTION OF THE MOTOR WITH BELT PULLEY DRIVE MECHANISM

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 The ideal gearmotor can be created for every requirement. Whether you combine our PF..
planetary servo gear unit or BF.. helical servo gear unit with CMP synchronous servomotors,
DRL.. asynchronous servomotors, or DR.. AC motors: Every time, the special interplay between
motor and gear unit gives the exact drive response tailored to your application and requirements.
You can also create versatile combinations with the gear units from our standard range and our
servomotors to configure and optimize the individual drives in your plant.
The principal role in the gearmotor is performed by the gear unit and its gear unit stages,
the gear pairs. These features transmit the force of the motor from the input end to the output end.
The gear unit therefore functions as a converter of speed and torque. Another important measured
variable for a gearmotor is the maximum torque on the output side. This torque is specified in
newton meters (Nm) and is the measurement for the force of the gearmotor and the load that it can
move with that force.
I have selected a pneumatic motor with magnet and sensor channel, which has as main
effect the fact that when the rod comes out, will push the pocket (or the tool pot) 90 degrees
outwards. For this particular application I chose a double acting single rod pneumatic actuator with
spring from the company FESTO you can see in Figure 12 and Annex III, because there are some
advantages to use double acting cylinders over single acting cylinders: more use of compressed
air, and as disadvantage: more wiring is needed for the system. Single acting cylinders also have
disadvantages: the spring takes up space and limits the working stroke of the cylinder.

FIGURE 12- PNEUMATIC STANDARD CYLINDER DNC ISO 15552 SECTION 32 (MM ) AND HIS PRICE

Source: https://www.festo.com/cat/engb_gb/data/doc_ENUS/PDF/US/DNC_ENUS.PDF
https://www.automatic.ro/cilindri-dnc-iso-15552/39-cilindru-pneumatic-standard-dnc.mm.html

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FIGURE 13- 3D VIEW OF THE PNEUMATIC MOTOR (PNEUMATIC CYLINDER )

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FIGURE 14-3D VIEW OF THE TOOL HOLDER AND THE POCKET (BEFORE ADDING PNEUMATIC CYLINDER)

FIGURE 15- 3D VIEW POCKET WITH THE TOOL HOLDER PUSHED AT 90 DEGREES OUTWARDS

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FIGURE 16- 3D VIEW OF THE DISK TYPE TOOL MAGAZINE WHEN POCKET WITH THE TOOL
HOLDER PUSHED AT 90 DEGREES OUTWARDS

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 2.2 Drive Mechanism

The drive mechanism is a belt-pulley drive mechanism. For this I used the web-based
calculator from the link specified below. Two pulleys can be used to create a simple belt and pulley
system, in which a belt is looped between the two pulleys. One pulley is the "driving pulley", and
as it spins, it transmits power through the belt either via friction or teeth, thus spinning a "driven
pulley". The output results are presented in Figure 17:

FIGURE 17- SPECIFICATION FOR BELT-PULLEY DRIVE MECHANISM

Source: https://www.bbman.com/belt-length-calculator/
https://www.instructables.com/id/Basic-Pulley-Mechanisms/

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FIGURE 18-3D VIEW OF THE BELT PULLEY DRIVE MECHANISM

FIGURE 19-3D VIEW OF THE BELT PULLEY DRIVE MECHANISM

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FIGURE 20- 3D VIEW OF THE PULLEY (GEAR)

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FIGURE 21- 2D VIEW OF THE PULLEY (GEAR) WITH OVERALL DIMENSIONS

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FIGURE 22- 2D VIEW OF THE THE SHAFT MODEL WITH OVERALL DIMENSIONS

FIGURE 23- 2D VIEW OF THE SHAFT MODEL

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 2.3. Bearings

There are many types of bearings, each used for different purposes. Bearings are an
important element to many machines, as they reduce friction between two objects, allowing
moving parts to move more smoothly. I choose deep groove ball bearings, based on the sizing
engine at : http://webtools3.skf.com/BearingCalc/selectProduct.action .

FIGURE 24- CHOSING OF BEARINGS BASED ON SIZING ENGINE

Source: http://webtools3.skf.com/BearingCalc/selectProduct.action

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 FIGURE 25- 3D VIEW WHERE THE BEARINGS ARE HIGHLIGHTED

FIGURE 26- DEEP GROOVE BALL BEARINGS

Source:https://www.schaeffler.ro/content.schaeffler.ro/ro/rolling_and_plain_bearings/
deep_groove_ball_bearing/index. jsp

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 2.4. Tool holders and pockets

These pockets ensure safely the tool holders during every process. They are design in
such way to perform a translation so the ATC can grab the tool easily, so I have attached 3D
model for pocket and tool holder (Figure 14 and Figure 15). The main used tool holder for this
type is ISO, so I choose Regio-Fix ISO40ER (Figure 16).

FIGURE 27- 3D VIEW OF THE POCKET

FIGURE 28- 3D VIEW OF THE TOOL HOLDER

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 FIGURE 29- TOOL HOLDER REGIO-FIX ISO40ER

FIGURE 30-3D VIEW OF THE TOOL HOLDER AND THE POCKET

(BEFORE ADDING PNEUMATIC CYLINDER)

Source: http://www.toolexpert.ee/Kataloogid/REGO-FIX-TotalTooling2011.pd

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 2.5. Sensors selection

The sensor that I selected for the magazine (Figure 17) is an object recognition
sensor. It can identify the tool on the pot and transfer the data into the system so that
it can stop at the exchange position. I choose SN series proximity sensor to keep
tracking when a specific tool needs to be used so that it would be positioned in the
desired place.
This inductive proximity sensor will detect the presence of a metallic object
within 5mm of the surface of the sensor. The detection distance may vary slightly
depending on the shape, size, and type of metal the object is made of. It can detect
through thin, non-metallic materials and has an LED indicator that turns on when
the device is powered, and increases in brightness when an object is detected.

FIGURE 32-3 D DRAWING OF THE SENSOR , WITH THE

TOOL HOLDER

FIGURE 31- OBJECT RECOGNITION SENSOR , DRAWING

Source: https://www.sensirion.com/en/

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 2.6. Assembly drawing

FIGURE - ASSEMBLY DRAWING FOR THE DISK TYPE TOOL MAGAZINE

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 Labor protection

 When a malfunction occurs, the device will be removed from work and the damaged part will
be replaced;
 It is preferable for edges and corners to be designed to reduce the risk of accidents;
 It is preferable that the parts of the mechanism to be painted in order not to rust;
 Areas where there are moving rotation organs will be protected with the help of defenders;
 Follow the maintenance rules of the device;

Advantages and Disadvantages

The advantages of this tool magazine are the following:

 It can hold a large variety of tools

 From the technical point of view it has an quickly and easy maintenance
 It has an ergonomic design which fits perfectly to industry requirements

The disadvantage of this tool magazine is the following:

 high cost for the materials and tools.

Conclusions
In conclusion, this Disk Type Tool Magazine is suitable for applications on CNC milling
machines, vertical and horizontal machining centers, CNC lathes and multi-tasking machines. At
the end it was designed and manufactured to accommodate a high quantity of tool holders in a
restricted area and are particularly suitable for use on smaller machine tools. This project is a base
foundation for an engineering field that can cover other aspects from other engineering subjects.
The tool magazine is an important, and it must be a non-absent part of a process where is needed
Numerical Control machining.

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 3. Bill of Materials

Item code Item Material Quantity Total Observations

price
MF100 Magazine Steel E335 1 - Custom made for
frame every client, the
price depends
upon the size and
the number of tools
TP101 Tool pot Plastic 30 - Custom made
ABS
DGB102 Deep- Steel E355 - 1-5 $ Bought from
groove Ball USD* commerce
Bearings
BPD103 Belt Pulley - 1 - Custom made
Drive
PC104 Pneumatic - 30,47$ Bought from
Cylinder commerce(FESTO)
SM105 Servo- - 1 500-1500 Bought from
motor $ commerce
WG106 Worm Steel E335 1 - Bought from
gearbox commerce
IPS107 Inductive 1 Bought from
Proximity - 69,71$ commerce
Sensors
ISO108 ISO40ER Steel E355 - - Bought from
commerce

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Annexes I

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32
33
34
35
36
ANNEX II

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38
ANNEX III

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 5. Bibliography:

[1] Gokler, M.I., Koc, M.B., (1997)-„Design of an automatic tool changer with disc magazine
for a CNC horizontal machining center”, International Journal of Machine Tools and
Manufacture, Vol. 37, No. 3, 1997, pages 277-286

[2] https://en.wikipedia.org/wiki/Automatic_tool_changer

[3] Constantin, G., Ghionea, A. & Zapciu, M. (2007)-„Structural Configuration Methods for
Machine Tools”, 7𝑡ℎ International Multidisciplinary Conference, May 17-18, 2007, Romania,
ISSN: 1224- 3264 , pages 107-114, Baia Mare

[4] http://www.orientalmotor.com/motor-sizing/

[5] https://www.haascnc.com/productivity/tool-changer/smtc-30-hsk-hs.html

[6] J.E. Shigley and C.R Mischke -„Mechanical Engineering Design”, McGraw Hill
Publication, 5th Edition. 1989

[7] https://www.sew-eurodrive.de/products/gearmotors/gearmotors.html

[8] https://www.bbman.com/belt-length-calculator/

[9] Yan, H. S., Yiou, C.W., Chen, F. C. & Chang, P. (1995)-„On the classification of automatic
tool changers for machining centers”, Proceedings of ASME 1995 Design Engineering Technical
Conferences, 1995, USA, Vol. 1, DE (82), pages 931-936, Boston

[10] https://www.instructables.com/id/Basic-Pulley-Mechanisms/

[11] http://webtools3.skf.com/BearingCalc/selectProduct.action

[12] https://www.schaeffler.ro/content.schaeffler.ro/ro/rolling_and_plain_bearings/deep_g
roove_ball_bearing/index. jsp

[13] http://www.toolexpert.ee/Kataloogid/REGO-FIX-TotalTooling2011.pdf

[14] https://www.sensirion.com/en/

[15] http://www.toolexpert.ee/Kataloogid/REGO-FIX-TotalTooling2011.pdf

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