Abstract: Human consumption of the Earth's resources increases the need for a sustainable development as an important ecological, social, and economic theme. Re-engineering of machine tools, in terms of design and failure analysis, is defined as steps performed on an obsolete machine to return it to a new machine with the warranty that matches the customer requirement. To understand the future fatigue behavior of the used machine components, it is important to investigate the possible causes of machine parts failure through design, surface, and material inspections. In this study, the failure modes of the shaft of the rotary draw bending machine are inspected. Furthermore, stress and deflection analysis of the shaft subjected to combined torsion and bending loads are carried out by an analytical method and compared with a finite element analysis method. The theoretical fatigue strength, correction factors, and fatigue life sustained by the shaft before damaged are estimated by creating a stress-cycle (S-N) diagram. In conclusion, it is seen that the shaft can work in the second life, but it needs some surface treatments to increase the reliability and fatigue life.
Abstract: Monitoring of tool wear in milling operations is essential for achieving the desired dimensional accuracy and surface finish of a machined workpiece. Although there are numerous statistical models and artificial intelligence techniques available for monitoring the wear of cutting tools, these techniques cannot pin point which cutting edge of the tool, or which insert in the case of indexable tooling, is worn or broken. Currently, the task of monitoring the wear on the tool cutting edges is carried out by the operator who performs a manual inspection, causing undesirable stoppages of machine tools and consequently resulting in costs incurred from lost productivity. The present study is concerned with the development of a flute tracking system to segment signals related to each physical flute of a cutter with three flutes used in an end milling operation. The purpose of the system is to monitor the cutting condition for individual flutes separately in order to determine their progressive wear rates and to predict imminent tool failure. The results of this study clearly show that signals associated with each flute can be effectively segmented using the proposed flute tracking system. Furthermore, the results illustrate that by segmenting the sensor signal by flutes it is possible to investigate the wear in each physical cutting edge of the cutting tool. These findings are significant in that they facilitate the online condition monitoring of a cutting tool for each specific flute without the need for operators/engineers to perform manual inspections of the tool.
Abstract: Large-scale machine tools for the manufacturing of
large work pieces, e.g. blades, casings or gears for wind turbines,
feature pose-dependent dynamic behavior. Small structural damping
coefficients lead to long decay times for structural vibrations that
have negative impacts on the production process. Typically, these
vibrations are handled by increasing the stiffness of the structure by
adding mass. This is counterproductive to the needs of sustainable
manufacturing as it leads to higher resource consumption both in
material and in energy. Recent research activities have led to higher
resource efficiency by radical mass reduction that is based on controlintegrated
active vibration avoidance and damping methods. These
control methods depend on information describing the dynamic
behavior of the controlled machine tools in order to tune the
avoidance or reduction method parameters according to the current
state of the machine. This paper presents the appearance, consequences and challenges
of the pose-dependent dynamic behavior of lightweight large-scale
machine tool structures in production. It starts with the theoretical
introduction of the challenges of lightweight machine tool structures
resulting from reduced stiffness. The statement of the pose-dependent
dynamic behavior is corroborated by the results of the experimental
modal analysis of a lightweight test structure. Afterwards, the
consequences of the pose-dependent dynamic behavior of lightweight
machine tool structures for the use of active control and vibration
reduction methods are explained. Based on the state of the art of
pose-dependent dynamic machine tool models and the modal
investigation of an FE-model of the lightweight test structure, the
criteria for a pose-dependent model for use in vibration reduction are
derived. The description of the approach for a general posedependent
model of the dynamic behavior of large lightweight
machine tools that provides the necessary input to the aforementioned
vibration avoidance and reduction methods to properly tackle
machine vibrations is the outlook of the paper.
Abstract: In this article, the radial displacement error correction
capability of a high precision spindle grinding caused by unbalance
force was investigated. The spindle shaft is considered as a flexible
rotor mounted on two sets of angular contact ball bearing. Finite
element methods (FEM) have been adopted for obtaining the
equation of motion of the spindle. In this paper, firstly, natural
frequencies, critical frequencies, and amplitude of the unbalance
response caused by residual unbalance are determined in order to
investigate the spindle behaviors. Furthermore, an optimization
design algorithm is employed to minimize radial displacement of the
spindle which considers dimension of the spindle shaft, the dynamic
characteristics of the bearings, critical frequencies and amplitude of
the unbalance response, and computes optimum spindle diameters
and stiffness and damping of the bearings. Numerical simulation
results show that by optimizing the spindle diameters, and stiffness
and damping in the bearings, radial displacement of the spindle can
be reduced. A spindle about 4 μm radial displacement error can be
compensated with 2 μm accuracy. This certainly can improve the
accuracy of the product of machining.
Abstract: Chatter vibrations and process instabilities are the
most important factors limiting the productivity of the milling
process. Chatter can leads to damage of the tool, the part or the
machine tool. Therefore, the estimation and prediction of the process
stability is very important. The process stability depends on the
spindle speed, the depth of cut and the width of cut. In milling, the
process conditions are defined in the NC-program. While the spindle
speed is directly coded in the NC-program, the depth and width of cut
are unknown. This paper presents a new simulation based approach
for the prediction of the depth and width of cut of a milling process.
The prediction is based on a material removal simulation with an
analytically represented tool shape and a multi-dexel approach for the
workpiece. The new calculation method allows the direct estimation
of the depth and width of cut, which are the influencing parameters of
the process stability, instead of the removed volume as existing
approaches do. The knowledge can be used to predict the stability of
new, unknown parts. Moreover with an additional vibration sensor,
the stability lobe diagram of a milling process can be estimated and
improved based on the estimated depth and width of cut.
Abstract: To decrease the grating scale thermal expansion error,
a novel method which based on multiple temperature detection is
proposed. Several temperature sensors are installed on the grating
scale and the temperatures of these sensors are recorded. The
temperatures of every point on the grating scale are calculated by
interpolating between adjacent sensors. According to the thermal
expansion principle, the grating scale thermal expansion error model
can be established by doing the integral for the variations of position
and temperature. A novel compensation method is proposed in this
paper. By applying the established error model, the grating scale
thermal expansion error is decreased by 90% compared with no
compensation. The residual positioning error of the grating scale is
less than 15μm/10m and the accuracy of the machine tool is
significant improved.
Abstract: The spindle system is one of the most important
components of machine tool. The dynamic properties of the spindle
affect the machining productivity and quality of the work pieces.
Thus, it is important and necessary to determine its dynamic
characteristics of spindles in the design and development in order to
avoid forced resonance. The finite element method (FEM) has been
adopted in order to obtain the dynamic behavior of spindle system.
For this reason, obtaining the Campbell diagrams and determining the
critical speeds are very useful to evaluate the spindle system
dynamics. The unbalance response of the system to the center of
mass unbalance at the cutting tool is also calculated to investigate the
dynamic behavior. In this paper, we used an ANSYS Parametric
Design Language (APDL) program which based on finite element
method has been implemented to make the full dynamic analysis and
evaluation of the results. Results show that the calculated critical
speeds are far from the operating speed range of the spindle, thus, the
spindle would not experience resonance, and the maximum
unbalance response at operating speed is still with acceptable limit.
ANSYS Parametric Design Language (APDL) can be used by spindle
designer as tools in order to increase the product quality, reducing
cost, and time consuming in the design and development stages.
Abstract: The capability of CNC gantry milling machines in
manufacturing long components has caused the expanded use of such
machines. On the other hand, the machines’ gantry rigidity can
reduce under severe loads or vibration during operation. Indeed, the
quality of machining is dependent on the machine’s dynamic
behavior throughout the operating process. For this reason, these
types of machines have always been used widely and are not
efficient. Therefore, they can usually be employed for rough
machining and may not produce adequate surface finishing. In this
paper, a CNC gantry milling machine with the potential to produce
good surface finish has been designed and analyzed. The lowest
natural frequency of this machine is 202 Hz corresponding to 12000
rpm at all motion amplitudes with a full range of suitable frequency
responses. Meanwhile, the maximum deformation under dead loads
for the gantry machine is 0.565*m, indicating that this machine tool
is capable of producing higher product quality.
Abstract: A novel simulation method to determine the
displacements of machine tools due to thermal factors is presented.
The specific characteristic of this method is the employment of
original CAD data from the design process chain, which is
interpreted by an algorithm in terms of geometry-based allocation of
convection and radiation parameters. Furthermore analogous models
relating to the thermal behaviour of machine elements are
automatically implemented, which were gained by extensive
experimental testing with thermography imaging. With this a
transient simulation of the thermal field and in series of the
displacement of the machine tool is possible simultaneously during
the design phase. This method was implemented and is already used
industrially in the design of machining centres in order to improve
the quality of herewith manufactured workpieces.
Abstract: Several researches have been conducted to study
consumption of energy in cutting process. Most of these researches
are focusing to measure the consumption and propose consumption
reduction methods. In this work, the relation between the cutting
parameters and the consumption is investigated in order to establish a
generalized energy consumption model that can be used for process
and production planning in real production lines. Using the
generalized model, the process planning will be carried out by taking
into account the energy as a function of the selected process
parameters. Similarly, the generalized model can be used in
production planning to select the right operational parameters like
batch sizes, routing, buffer size, etc. in a production line. The
description and derivation of the model as well as a case study are
given in this paper to illustrate the applicability and validity of the
model.
Abstract: Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.
Abstract: Five-axis computer numerical control (CNC) machine tools (three linear and two rotary axes) are ideally suited to the fabrication of complex work pieces, such as dies, turbo blades, and cams. The locations of the axis average line and centerline of the rotary axes strongly influence the performance of these machines; however, techniques to compensate for eccentric error in the rotary axes remain weak. This paper proposes optical (Non-Bar) techniques capable of calibrating five-axis CNC machine tools and compensating for eccentric error in the rotary axes. This approach employs the measurement path in ISO/CD 10791-6 to determine the eccentric error in two rotary axes, for which compensatory measures can be implemented. Experimental results demonstrate that the proposed techniques can improve the performance of various five-axis CNC machine tools by more than 90%. Finally, a result of the cutting test using a B-type five-axis CNC machine tool confirmed to the usefulness of this proposed compensation technique.
Abstract: The performance of a machine tool is eventually assessed by its ability to produce a component of the required geometry in minimum time and at small operating cost. It is customary to base the structural design of any machine tool primarily upon the requirements of static rigidity and minimum natural frequency of vibration. The operating properties of machines like cutting speed, feed and depth of cut as well as the size of the work piece also have to be kept in mind by a machine tool structural designer. This paper presents a novel approach to the design of machine tool column for static and dynamic rigidity requirement. Model evaluation is done effectively through use of General Finite Element Analysis software ANSYS. Studies on machine tool column are used to illustrate finite element based concept evaluation technique. This paper also presents results obtained from the computations of thin walled box type columns that are subjected to torsional and bending loads in case of static analysis and also results from modal analysis. The columns analyzed are square and rectangle based tapered open column, column with cover plate, horizontal partitions and with apertures. For the analysis purpose a total of 70 columns were analyzed for bending, torsional and modal analysis. In this study it is observed that the orientation and aspect ratio of apertures have no significant effect on the static and dynamic rigidity of the machine tool structure.
Abstract: The characterization and modeling of the dynamic
behavior of many built-up structures under vibration conditions is still
a subject of current research. The present study emphasizes the
theoretical investigation of slip damping in layered and jointed
welded cantilever structures using finite element approach.
Application of finite element method in damping analysis is relatively
recent, as such, some problems particularly slip damping analysis has
not received enough attention. To validate the finite element model
developed, experiments have been conducted on a number of mild
steel specimens under different initial conditions of vibration. Finite
element model developed affirms that the damping capacity of such
structures is influenced by a number of vital parameters such as;
pressure distribution, kinematic coefficient of friction and micro-slip
at the interfaces, amplitude, frequency of vibration, length and
thickness of the specimen. Finite element model developed can be
utilized effectively in the design of machine tools, automobiles,
aerodynamic and space structures, frames and machine members for
enhancing their damping capacity.
Abstract: Automated production lines with so called 'hard structures' are widely used in manufacturing. Designers segmented these lines into sections by placing a buffer between the series of machine tools to increase productivity. In real production condition the capacity of a buffer system is limited and real production line can compensate only some part of the productivity losses of an automated line. The productivity of such production lines cannot be readily determined. This paper presents mathematical approach to solving the structure of section-based automated production lines by criterion of maximum productivity.
Abstract: Machine tools are improved capacity remarkably during the 20th century. Improving the precision of machine tools are related with precision of products and accurate processing is always associated with the subject of interest. There are a lot of the elements that determine the precision of the machine, as guides, motors, structure, control, etc. In this paper we focused on the phenomenon that vertical movement system has worse precision than horizontal movement system even they were made up with same components. The vertical movement system needs to be studied differently from the horizontal movement system to develop its precision. The vertical movement system has load on its transfer direction and it makes the movement system weak in precision than the horizontal one. Some machines have mechanical counter balance, hydraulic or pneumatic counter balance to compensate the weight of the machine head. And there is several type of compensating the weight. It can push the machine head and also can use chain or wire lope to transfer the compensating force from counter balance to machine head. According to the type of compensating, there could be error from friction, pressure error of hydraulic or pressure control error. Also according to what to use for transferring the compensating force, transfer error of compensating force could be occur.
Abstract: This paper introduces a novel design for boring bar with enhanced damping capability. The principle followed in the design phase was to enhance the damping capability minimizing the loss in static stiffness through implementation of composite material interfaces. The newly designed tool has been compared to a conventional tool. The evaluation criteria were the dynamic characteristics, frequency and damping ratio, of the machining system, as well as the surface roughness of the machined workpieces. The use of composite material in the design of damped tool has been demonstrated effective. Furthermore, the autoregressive moving average (ARMA) models presented in this paper take into consideration the interaction between the elastic structure of the machine tool and the cutting process and can therefore be used to characterize the machining system in operational conditions.
Abstract: Chatter vibration has been a troublesome problem
for a machine tool toward the high precision and high speed machining.
Essentially, the machining performance is determined by the dynamic
characteristics of the machine tool structure and dynamics of cutting
process, which can further be identified in terms of the stability lobe
diagram. Therefore, realization on the machine tool dynamic behavior
can help to enhance the cutting stability. To assess the dynamic
characteristics and machining stability of a vertical milling system
under the influence of a linear guide, this study developed a finite
element model integrated the modeling of linear components with the
implementation of contact stiffness at the rolling interface. Both the
finite element simulations and experimental measurements reveal that
the linear guide with different preload greatly affects the vibration
behavior and milling stability of the vertical column spindle head
system, which also clearly indicate that the predictions of the
machining stability agree well with the cutting tests. It is believed that
the proposed model can be successfully applied to evaluate the
dynamics performance of machine tool systems of various
configurations.
Abstract: One of the most important problems in production planning of flexible manufacturing system (FMS) is machine tool selection and operation allocation problem that directly influences the production costs and times .In this paper minimizing machining cost, set-up cost and material handling cost as a multi-objective problem in flexible manufacturing systems environment are considered. We present a 0-1 integer linear programming model for the multiobjective machine tool selection and operation allocation problem and due to the large scale nature of the problem, solving the problem to obtain optimal solution in a reasonable time is infeasible, Paretoant colony optimization (P-ACO) approach for solving the multiobjective problem in reasonable time is developed. Experimental results indicate effectiveness of the proposed algorithm for solving the problem.
Abstract: This paper proposes method of diagnosing ball screw
preload loss through the Hilbert-Huang Transform (HHT) and
Multiscale entropy (MSE) process. The proposed method can
diagnose ball screw preload loss through vibration signals when the
machine tool is in operation. Maximum dynamic preload of 2 %, 4 %,
and 6 % ball screws were predesigned, manufactured, and tested
experimentally. Signal patterns are discussed and revealed using
Empirical Mode Decomposition(EMD)with the Hilbert Spectrum.
Different preload features are extracted and discriminated using HHT.
The irregularity development of a ball screw with preload loss is
determined and abstracted using MSE based on complexity
perception. Experiment results show that the proposed method can
predict the status of ball screw preload loss. Smart sensing for the
health of the ball screw is also possible based on a comparative
evaluation of MSE by the signal processing and pattern matching of
EMD/HHT. This diagnosis method realizes the purposes of prognostic
effectiveness on knowing the preload loss and utilizing convenience.