Scholarly

New Regression Model and I-Kaz Method for Online Cutting Tool Wear Monitoring

Year: 2009 Volume: 3 Issue: 12 1642 - 1647 Pages

Abstract: This study presents a new method for detecting the cutting tool wear based on the measured cutting force signals using the regression model and I-kaz method. The detection of tool wear was done automatically using the in-house developed regression model and 3D graphic presentation of I-kaz 3D coefficient during machining process. The machining tests were carried out on a CNC turning machine Colchester Master Tornado T4 in dry cutting condition, and Kistler 9255B dynamometer was used to measure the cutting force signals, which then stored and displayed in the DasyLab software. The progression of the cutting tool flank wear land (VB) was indicated by the amount of the cutting force generated. Later, the I-kaz was used to analyze all the cutting force signals from beginning of the cut until the rejection stage of the cutting tool. Results of the IKaz analysis were represented by various characteristic of I-kaz 3D coefficient and 3D graphic presentation. The I-kaz 3D coefficient number decreases when the tool wear increases. This method can be used for real time tool wear monitoring.

A Strategy to Optimize the SPC Scheme for Mass Production of HDD Arm with ClusteringTechnique and Three-Way Control Chart

Year: 2008 Volume: 2 Issue: 6 825 - 828 Pages

Authors:
W. Chattinnawat

Abstract: Consider a mass production of HDD arms where hundreds of CNC machines are used to manufacturer the HDD arms. According to an overwhelming number of machines and models of arm, construction of separate control chart for monitoring each HDD arm model by each machine is not feasible. This research proposed a strategy to optimize the SPC management on shop floor. The procedure started from identifying the clusters of the machine with similar manufacturing performance using clustering technique. The three way control chart ( I - MR - R ) is then applied to each clustered group of machine. This proposed research has advantageous to the manufacturer in terms of not only better performance of the SPC but also the quality management paradigm.

Analysis of Chatter in Ball End Milling by Wavelet Transform

Year: 2012 Volume: 6 Issue: 11 2573 - 2579 Pages

Authors:
S. Tangjitsitcharoen

Abstract: The chatter is one of the major limitations of the productivity in the ball end milling process. It affects the surface roughness, the dimensional accuracy and the tool life. The aim of this research is to propose the new system to detect the chatter during the ball end milling process by using the wavelet transform. The proposed method is implemented on the 5-axis CNC machining center and the new three parameters are introduced from three dynamic cutting forces, which are calculated by taking the ratio of the average variances of dynamic cutting forces to the absolute variances of themselves. It had been proved that the chatter can be easier to detect during the in-process cutting by using the new parameters which are proposed in this research. The experimentally obtained results showed that the wavelet transform can provide the reliable results to detect the chatter under various cutting conditions.

Development of Machinable Ellipses by NURBS Curves

Year: 2008 Volume: 2 Issue: 2 209 - 216 Pages

Abstract: Owning to the high-speed feed rate and ultra spindle speed have been used in modern machine tools, the tool-path generation plays a key role in the successful application of a High-Speed Machining (HSM) system. Because of its importance in both high-speed machining and tool-path generation, approximating a contour by NURBS format is a potential function in CAD/CAM/CNC systems. It is much more convenient to represent an ellipse by parametric form than to connect points laboriously determined in a CNC system. A new approximating method based on optimum processes and NURBS curves of any degree to the ellipses is presented in this study. Such operations can be the foundation of tool-radius compensation interpolator of NURBS curves in CNC system. All operating processes for a CAD tool is presented and demonstrated by practical models.

Feature-Based Machining using Macro

Year: 2012 Volume: 6 Issue: 8 1133 - 1137 Pages

Abstract: This paper presents an on-going research work on the implementation of feature-based machining via macro programming. Repetitive machining features such as holes, slots, pockets etc can readily be encapsulated in macros. Each macro consists of methods on how to machine the shape as defined by the feature. The macro programming technique comprises of a main program and subprograms. The main program allows user to select several subprograms that contain features and define their important parameters. With macros, complex machining routines can be implemented easily and no post processor is required. A case study on machining of a part that comprised of planar face, hole and pocket features using the macro programming technique was carried out. It is envisaged that the macro programming technique can be extended to other feature-based machining fields such as the newly developed STEP-NC domain.

Efficient CNC Milling by Adjusting Material Removal Rate

Year: 2011 Volume: 5 Issue: 10 2047 - 2051 Pages

Authors:
Majid Tolouei-Rad

Abstract: This paper describes a combined mathematicalgraphical approach for optimum tool path planning in order to improve machining efficiency. A methodology has been used that stabilizes machining operations by adjusting material removal rate in pocket milling operations while keeping cutting forces within limits. This increases the life of cutting tool and reduces the risk of tool breakage, machining vibration, and chatter. Case studies reveal the fact that application of this approach could result in a slight increase of machining time, however, a considerable reduction of tooling cost, machining vibration, noise and chatter can be achieved in addition to producing a better surface finish.

Evaluation of Fuzzy ARTMAP with DBSCAN in VLSI Application

Year: 2007 Volume: 1 Issue: 12 4012 - 4015 Pages

Abstract: The various applications of VLSI circuits in highperformance computing, telecommunications, and consumer electronics has been expanding progressively, and at a very hasty pace. This paper describes a new model for partitioning a circuit using DBSCAN and fuzzy ARTMAP neural network. The first step is concerned with feature extraction, where we had make use DBSCAN algorithm. The second step is the classification and is composed of a fuzzy ARTMAP neural network. The performance of both approaches is compared using benchmark data provided by MCNC standard cell placement benchmark netlists. Analysis of the investigational results proved that the fuzzy ARTMAP with DBSCAN model achieves greater performance then only fuzzy ARTMAP in recognizing sub-circuits with lowest amount of interconnections between them The recognition rate using fuzzy ARTMAP with DBSCAN is 97.7% compared to only fuzzy ARTMAP.

Flexible Manufacturing System

Year: 2011 Volume: 5 Issue: 5 910 - 914 Pages

Abstract: Flexible manufacturing system is a system that is able to respond to changed conditions. In general, this flexibility is divided into two key categories and several subcategories. The first category is the so called machine flexibility which enables to make various products by the given machinery. The second category is routing flexibility enabling to execute the same operation by various machines. Flexible manufacturing systems usually consist of three main parts: CNC machine tools, transport system and control system. A higher level of flexible manufacturing systems is represented by the so called intelligent manufacturing systems.

Real Time Compensation of Machining Errors for Machine Tools NC based on Systematic Dispersion

Year: 2009 Volume: 3 Issue: 8 948 - 954 Pages

Abstract: Manufacturing tolerancing is intended to determine the intermediate geometrical and dimensional states of the part during its manufacturing process. These manufacturing dimensions also serve to satisfy not only the functional requirements given in the definition drawing, but also the manufacturing constraints, for example geometrical defects of the machine, vibration and the wear of the cutting tool. In this paper, an experimental study on the influence of the wear of the cutting tool (systematic dispersions) is explored. This study was carried out on three stages .The first stage allows machining without elimination of dispersions (random, systematic) so the tolerances of manufacture according to total dispersions. In the second stage, the results of the first stage are filtered in such way to obtain the tolerances according to random dispersions. Finally, from the two previous stages, the systematic dispersions are generated. The objective of this study is to model by the least squares method the error of manufacture based on systematic dispersion. Finally, an approach of optimization of the manufacturing tolerances was developed for machining on a CNC machine tool

Feedrate Optimization for Ball-end milling of Sculptured Surfaces using Fuzzy Logic Controller

Year: 2011 Volume: 5 Issue: 8 1622 - 1630 Pages

Abstract: Optimization of cutting parameters important in precision machining in regards to efficiency and surface integrity of the machined part. Usually productivity and precision in machining is limited by the forces emanating from the cutting process. Due to the inherent varying nature of the workpiece in terms of geometry and material composition, the peak cutting forces vary from point to point during machining process. In order to increase productivity without compromising on machining accuracy, it is important to control these cutting forces. In this paper a fuzzy logic control algorithm is developed that can be applied in the control of peak cutting forces in milling of spherical surfaces using ball end mills. The controller can adaptively vary the feedrate to maintain allowable cutting force on the tool. This control algorithm is implemented in a computer numerical control (CNC) machine. It has been demonstrated that the controller can provide stable machining and improve the performance of the CNC milling process by varying feedrate.

Remote Operation of CNC Milling Through Virtual Simulation and Remote Desktop Interface

Year: 2009 Volume: 3 Issue: 5 559 - 562 Pages

Abstract: Increasing the demand for effectively use of the production facility requires the tools for sharing the manufacturing facility through remote operation of the machining process. This research introduces the methodology of machining technology for direct remote operation of networked milling machine. The integrated tools with virtual simulation, remote desktop protocol and Setup Free Attachment for remote operation of milling process are proposed. Accessing and monitoring of machining operation is performed by remote desktop interface and 3D virtual simulations. Capability of remote operation is supported by an auto setup attachment with a reconfigurable pin type setup free technology installed on the table of CNC milling machine to perform unattended machining process. The system is designed using a computer server and connected to a PC based controlled CNC machine for real time monitoring. A client will access the server through internet communication and virtually simulate the machine activity. The result has been presented that combination between real time virtual simulation and remote desktop tool is enabling to operate all machine tool functions and as well as workpiece setup..

CNC Wire-Cut Parameter Optimized Determination of the Stair Shape Workpiece

Year: 2010 Volume: 4 Issue: 10 1056 - 1061 Pages

Abstract: The objective of this research is parameters optimized of the stair shape workpiece which is cut by CNC Wire-Cut EDM (WEDW). The experiment material is SKD-11 steel of stair-shaped with variable height workpiece 10, 20, 30 and 40 mm. with the same 10 mm. thickness are cut by Sodick's CNC Wire-Cut EDM model AD325L. The experiments are designed by 3k full factorial experimental design at 3 level 2 factors and 9 experiments with 2 replicate. The selected two factor are servo voltage (SV) and servo feed rate (SF) and the response is cutting thickness error. The experiment is divided in two experiments. The first experiment determines the significant effective factor at confidential interval 95%. The SV factor is the significant effective factor from first result. In order to result smallest cutting thickness error of workpieces is 17 micron with the SV value is 46 volt. Also show that the lower SV value, the smaller different thickness error of workpiece. Then the second experiment is done to reduce different cutting thickness error of workpiece as small as possible by lower SV. The second experiment result show the significant effective factor at confidential interval 95% is the SV factor and the smallest cutting thickness error of workpieces reduce to 11 micron with the experiment SV value is 36 volt.

Hazardous Waste Management of Transmission Line Tower Manufacturing

Year: 2010 Volume: 4 Issue: 12 662 - 665 Pages

Abstract: The manufacturing transmission line tower parts has being generated hazardous waste which is required proper disposal of waste for protection of land pollution. Manufacturing Process in the manufacturing of steel angle, plates, pipes, channels are passes through conventional, semi automatic and CNC machines for cutting, marking, punching, drilling, notching, bending operations. All fabricated material Coated with thin layer of Zinc in Galvanizing plant where molten zinc is used for coating. Prior to Galvanizing, chemical like 33% concentrated HCl Acid, ammonium chloride and d-oil being used for pretreatment of iron. The bath of water with sodium dichromate is used for cooling and protection of the galvanized steel. For the heating purpose the furnace oil burners are used. These above process the Zinc dross, Zinc ash, ETP sludge and waste pickled acid generated as hazardous waste. The RPG has made captive secured land fill site, since 1997 since then it was using for disposal of hazardous waste after completion of SLF (Secured land fill) site. The RPG has raised height from ground level then now it is being used for disposal of waste as he designed the SLF after in creasing height of from GL it is functional without leach ate or adverse impacts in the environment.

Machine Scoring Model Using Data Mining Techniques

Year: 2010 Volume: 4 Issue: 4 756 - 760 Pages

Abstract: this article proposed a methodology for computer numerical control (CNC) machine scoring. The case study company is a manufacturer of hard disk drive parts in Thailand. In this company, sample of parts manufactured from CNC machine are usually taken randomly for quality inspection. These inspection data were used to make a decision to shut down the machine if it has tendency to produce parts that are out of specification. Large amount of data are produced in this process and data mining could be very useful technique in analyzing them. In this research, data mining techniques were used to construct a machine scoring model called 'machine priority assessment model (MPAM)'. This model helps to ensure that the machine with higher risk of producing defective parts be inspected before those with lower risk. If the defective prone machine is identified sooner, defective part and rework could be reduced hence improving the overall productivity. The results showed that the proposed method can be successfully implemented and approximately 351,000 baht of opportunity cost could have saved in the case study company.

A Set Theory Based Factoring Technique and Its Use for Low Power Logic Design

Year: 2007 Volume: 1 Issue: 3 641 - 651 Pages

Abstract: Factoring Boolean functions is one of the basic operations in algorithmic logic synthesis. A novel algebraic factorization heuristic for single-output combinatorial logic functions is presented in this paper and is developed based on the set theory paradigm. The impact of factoring is analyzed mainly from a low power design perspective for standard cell based digital designs in this paper. The physical implementation of a number of MCNC/IWLS combinational benchmark functions and sub-functions are compared before and after factoring, based on a simple technology mapping procedure utilizing only standard gate primitives (readily available as standard cells in a technology library) and not cells corresponding to optimized complex logic. The power results were obtained at the gate-level by means of an industry-standard power analysis tool from Synopsys, targeting a 130nm (0.13μm) UMC CMOS library, for the typical case. The wire-loads were inserted automatically and the simulations were performed with maximum input activity. The gate-level simulations demonstrate the advantage of the proposed factoring technique in comparison with other existing methods from a low power perspective, for arbitrary examples. Though the benchmarks experimentation reports mixed results, the mean savings in total power and dynamic power for the factored solution over a non-factored solution were 6.11% and 5.85% respectively. In terms of leakage power, the average savings for the factored forms was significant to the tune of 23.48%. The factored solution is expected to better its non-factored counterpart in terms of the power-delay product as it is well-known that factoring, in general, yields a delay-efficient multi-level solution.

Condition Monitoring in the Management of Maintenance in a Large Scale Precision CNC Machining Manufacturing Facility

Year: 2012 Volume: 6 Issue: 8 1631 - 1634 Pages

Abstract: The manufacture of large-scale precision aerospace components using CNC requires a highly effective maintenance strategy to ensure that the required accuracy can be achieved over many hours of production. This paper reviews a strategy for a maintenance management system based on Failure Mode Avoidance, which uses advanced techniques and technologies to underpin a predictive maintenance strategy. It is shown how condition monitoring (CM) is important to predict potential failures in high precision machining facilities and achieve intelligent and integrated maintenance management. There are two distinct ways in which CM can be applied. One is to monitor key process parameters and observe trends which may indicate a gradual deterioration of accuracy in the product. The other is the use of CM techniques to monitor high status machine parameters enables trends to be observed which can be corrected before machine failure and downtime occurs. It is concluded that the key to developing a flexible and intelligent maintenance framework in any precision manufacturing operation is the ability to evaluate reliably and routinely machine tool condition using condition monitoring techniques within a framework of Failure Mode Avoidance.

Interoperable CNC System for Turning Operations

Year: 2009 Volume: 3 Issue: 1 61 - 67 Pages

Abstract: The changing economic climate has made global manufacturing a growing reality over the last decade, forcing companies from east and west and all over the world to collaborate beyond geographic boundaries in the design, manufacture and assemble of products. The ISO10303 and ISO14649 Standards (STEP and STEP-NC) have been developed to introduce interoperability into manufacturing enterprises so as to meet the challenge of responding to production on demand. This paper describes and illustrates a STEP compliant CAD/CAPP/CAM System for the manufacture of rotational parts on CNC turning centers. The information models to support the proposed system together with the data models defined in the ISO14649 standard used to create the NC programs are also described. A structured view of a STEP compliant CAD/CAPP/CAM system framework supporting the next generation of intelligent CNC controllers for turn/mill component manufacture is provided. Finally a proposed computational environment for a STEP-NC compliant system for turning operations (SCSTO) is described. SCSTO is the experimental part of the research supported by the specification of information models and constructed using a structured methodology and object-oriented methods. SCSTO was developed to generate a Part 21 file based on machining features to support the interactive generation of process plans utilizing feature extraction. A case study component has been developed to prove the concept for using the milling and turning parts of ISO14649 to provide a turn-mill CAD/CAPP/CAM environment.

Keywords:

A Study on the Quality of Hexapod Machine Tool's Workspace

Year: 2009 Volume: 3 Issue: 4 386 - 391 Pages

Abstract: One of the main concerns about parallel mechanisms is the presence of singular points within their workspaces. In singular positions the mechanism gains or loses one or several degrees of freedom. It is impossible to control the mechanism in singular positions. Therefore, these positions have to be avoided. This is a vital need especially in computer controlled machine tools designed and manufactured on the basis of parallel mechanisms. This need has to be taken into consideration when selecting design parameters. A prerequisite to this is a thorough knowledge about the effect of design parameters and constraints on singularity. In this paper, quality condition index was introduced as a criterion for evaluating singularities of different configurations of a hexapod mechanism obtainable by different design parameters. It was illustrated that this method can effectively be employed to obtain the optimum configuration of hexapod mechanism with the aim of avoiding singularity within the workspace. This method was then employed to design the hexapod table of a CNC milling machine.

Low Cost Chip Set Selection Algorithm for Multi-way Partitioning of Digital System

Year: 2012 Volume: 6 Issue: 2 223 - 225 Pages

Abstract: This paper considers the problem of finding low cost chip set for a minimum cost partitioning of a large logic circuits. Chip sets are selected from a given library. Each chip in the library has a different price, area, and I/O pin. We propose a low cost chip set selection algorithm. Inputs to the algorithm are a netlist and a chip information in the library. Output is a list of chip sets satisfied with area and maximum partitioning number and it is sorted by cost. The algorithm finds the sorted list of chip sets from minimum cost to maximum cost. We used MCNC benchmark circuits for experiments. The experimental results show that all of chip sets found satisfy the multiple partitioning constraints.

Advance in Monitoring and Process Control of Surface Roughness

Year: 2013 Volume: 7 Issue: 7 1553 - 1557 Pages

Abstract: This paper presents an advance in monitoring and process control of surface roughness in CNC machine for the turning and milling processes. An integration of the in-process monitoring and process control of the surface roughness is proposed and developed during the machining process by using the cutting force ratio. The previously developed surface roughness models for turning and milling processes of the author are adopted to predict the inprocess surface roughness, which consist of the cutting speed, the feed rate, the tool nose radius, the depth of cut, the rake angle, and the cutting force ratio. The cutting force ratios obtained from the turning and the milling are utilized to estimate the in-process surface roughness. The dynamometers are installed on the tool turret of CNC turning machine and the table of 5-axis machining center to monitor the cutting forces. The in-process control of the surface roughness has been developed and proposed to control the predicted surface roughness. It has been proved by the cutting tests that the proposed integration system of the in-process monitoring and the process control can be used to check the surface roughness during the cutting by utilizing the cutting force ratio.

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