This paper describes possibilities of process and condition data acquisition on universal milling centers with Sinumerik 840D-sl control. The measurement and process data is gathered mostly with the present control system architecture of the machine tool. This internal data collection has been extended by additional sensors and an external measurement system to enable further and partially deeper analysis. This setup is also explained in this publication. The demonstrator together with the measuring system allows an investigation of the introduced components close to reality and the observation of the overall system at once. The latter is considered energetically on a comparative measurement to ascertain discrepancies in energy consumption between two different milling strategies for a pocket cycle.

The objective of this survey is to evolve a better understanding of the complex thermal interactions inside a motor spindle. Therefore, the thermal behavior is investigated based on a simulation model and experiments. In contrast to existing simulation models, which either performed a complex thermal examination or an elaborate flow-mechanical analysis, a thermal (Finite Element Method) and fluid mechanical (Computational Fluid Dynamics) coupled simulation model was developed. Based on a comparative analysis, the usability of the currently available boundary conditions is scrutinized.

Due to the increase of product complexity, 5 axes machining centers are becoming more and more important. Rotary tables are usually chosen for the 4th and 5th axis. Additional hydraulic or pneumatic mounting clamps are often needed on these tables. The feeding of the required media is realized by a so-called rotary manifold. For this application, commonly several rotary seals are used to seal the transmitted media. Different sealing materials, based on the carrier polymer PTFE, have been examined during this research. In tribological model tests, friction and wear characteristics have been investigated during an oscillating movement under dry run conditions and equal load spectrums (surface pressure). The counter running surfaces were specific textured as a result of various machining processes to research the effects of possible micro-and macroscopic patterning on the sealing system. The tribological behavior of the analyzed combinations and the topography of the counter surfaces have been evaluated.

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An examination of machining centers with high degree of automation showed that rotatory manifolds are critical components regarding functional reliability and efficiency. In order to get a better understanding of the interrelationships and involved mechanisms of the sealing system inside the rotatory manifolds, a corresponding rotatory seal test rig was developed. This study presents the necessary development process. More importantly, both of the analytical and simulative strength verification of the pressure chamber design is elucidated.