© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

DEVELOPMENT OF INTELLIGENT LAPPING SYSTEM ESTIMATION OF FINISHED SURFACE ROUGHNESS AND ITS IMPROVEMENT SPEED

Tetsuro IYAMA¹, Ikuo TANABE², Aung Lwin MOE², Kazuo YOSHI³, Fumiaki NASU^2
1Nagaoka University of Technology, Educational affairs section, Mechanics and Machinery Group
²Nagaoka University of Technology, Dept. of Mechanical Engineering
³Nagaoka University of Technology, Central Machine Shop

Abstract

The lapping process is one of the traditional finishing processes and generally it is conducted as manual process by skilled worker. The productivity of these manual processes is lower and difficult to control. Hence, we developed an automatic lapping system for moulds and dies. The lapping system consists of simple lapping tools and conventional milling machine. Several materials were machined as mirror like surface using the system. The lapping conditions are usually decided by skilled worker's experience or knowhow. Therefore, in this study, an intelligent lapping system with the optimum conditions calculated by the lapping model was developed. Specifically, the relationship between the finished quality (surface roughness Rz and improvement rate of Rz) and each parameter of the system, Vickers hardness of work piece and lapping head, lapping pressure, grain size, is investigated. Then, an intelligent lapping system is developed. Finally, the HPM31 are machined as confirmatory experiment by developed system with calculated lapping conditions. It is concluded from the result that: (1) The relationship between the surface roughness and lapping parameter was cleared. (2) The intelligent lapping system using the lapping model was developed. (3) The estimated limit surface roughness and improvement rate by calculated condition satisfactorily agreed with the experimental results.

Author Keywords :

abrasive machining, lapping, intelligent finishing

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

LAPPING FOR MIRROR-LIKE FINISH ON CYLINDRICAL INNER AND END SURFACES USING THE LATHE WITH LINEAR MOTOR

Aung Lwin MOE¹, Ikuo TANABE², Tetsuro IYAMA², Fumiaki NASU³,
¹Nagaoka University of Technology, Doctoral student at Dept. of Information Science and Control Engineering
²Nagaoka University of Technology, Dept. of Mechanical Engineeringing
³Nagaoka University of Technology, Master student at Dept. of Mechanical Engineering

Abstract

Lapping is an old traditional machining process that has been useful all along in the human history. Uniform surface finishing by manual hand lapping on cylindrical inner and end surfaces are very difficult. Additionally, the geometrical form accuracy and productivity are lower. In a previous study, the new lapping method for outer cylindrical surface using the lathe with linear motor has been reported. However, this method could not be applied directly for the cylindrical inner and end surfaces. Therefore, lapping for mirror-like finish on cylindrical inner and end surfaces using the lathe with linear motor is investigated. In this study, lapping tool was modified from previous study to be suited for the cylindrical inner and end surfaces. Then, lapping methods for inner and end surfaces were developed for uniform mirror-like finish. Surface roughness and geometrical form accuracy improvement were measured for both surfaces. The optimum conditions for high productivity and high quality mirror-like surfaces were investigated. It was concluded from the results that, the developed lapping system was able to process mirror-like surface on cylindrical inner and end surfaces. Moreover, the optimum conditions for the mirror-like surfaces were revealed experimentally.

Author Keywords :

lapping, linear motor lathe, mirror-like surface, high quality and productivity

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

HIGH SPEED LAPPING FOR MIRROR-LIKE FINISH USING THE LATHE WITH LINEAR MOTOR

Aung Lwin MOE¹, Ikuo TANABE², Tetsuro IYAMA², Fumiaki NASU³,
¹Nagaoka University of Technology, Doctoral student at Dept. of Information Science and Control Engineering
²Nagaoka University of Technology, Dept. of Mechanical Engineeringing
³Nagaoka University of Technology, Master student at Dept. of Mechanical Engineering

Abstract

Several machines with linear motor have been developed for high productivity. The characteristics of these machines are high speed, high acceleration and deceleration with stable behaviors of feed. Moreover, mirror-like surface is required to add high quality on the most products. In this study high speed lapping by using the lathe with linear motor was investigated for mirror-like surface. Lapping was performed after turning with the same lathe Lapping tool consists of a lapping head, a spring and holder on the tool post to assemble the linear motor lathe. The spring is used to supply lapping pressure. Lapping slurry consists of water, PEO ( Polyethylene Oxide) and diamond grain. This slurry was supplied between a work piece and lapping head. Then, high speed lapping was performed. During the process, the lapping head temporarily left from work surface in order to catch some new grains and removed some chips. The optimum combination of both the spindle speed and the feed speed was investigated for high quality and productivity experimentally. Surface roughness and form accuracy were measured. It was concluded from the results that (1) Mirror-like surface was obtained by the high speed lapping, and (2) Optimun conditions for efficient high speed lapping was revealed experimentally

Author Keywords :

high speed lapping, linear motor lathe, mirror-like surface, high quality and productivity

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

AN APPLICATION OF HILBERT-HUANG TRANSFORM AND PRINCIPAL COMPONENT ANALYSIS FOR DIAGNOSTICS OF CYLINDRICAL PLUNGE GRINDING PROCESS

Paweł LAJMERT^1
1 Technical University of Lódź, Institute of Machine Tools and Production Engineering, Poland

Abstract

This paper presents a sensor based diagnostic system for a cylindrical plunge grinding process which ensures a reliable process state and tool wear identification. A new signal processing technique, i.e. Hilbert-Huang transform (HHT) was evaluated for this purpose based on the vibration and acoustic emission signal measurements. Numerical and experimental studies have demonstrated that the process state and tool wear may be effectivel detected through a statistical analysis of the time-dependent amplitudes and instantaneous frequencies resulting from the HHT. A principal component analysis was used to diagnose different grinding process states.

Author Keywords :

diagnostics, plunge grinding, Hilbert-Huang transform

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

A STUDY ON THE DEVELOPMENT OF A NEW GRINDING PROCESSES FOR HIGH-LEAD BALL SCREW NUTS

Chihyuk CHOI¹, Yanghyup HA², Hyunku KIM³, Choonman LEE^4
1K-MEM R&D Cluster, Changwon National University, Korea : cluster9@changwon.ac.kr
²Korea Institute of Materials Science : cluster6@changwon.ac.kr
³TIC Co., Ltd, Korea : hkim57@ticg.co.kr
⁴Department of Mechanical Design & Manufacturing Engineering, Changwon National University, Korea : cmlee@changwon.ac.kr (Corresponding author)

Abstract

This paper proposes a method that machines the race of high-lead ball screw nuts, which is difficult to machine using the existing geometrical machining method, without any interferences and changes in its load rating in order to perform the high-speed in ball screws. This study calculates the inclination angle of the axis of the grinding stone for avoiding the contact of the axis to the inner diamete of the nut and determines the shape of the grinding stone through changing the inclination angle and dressing curvature determined in a dressing device Then, the grinding condition will be determined by measuring the shape meter of the screw race for solving the problem. Also, the surface roughness of the grinded surface was measured using a surface roughness tester, and check with applying a grinding process of product not being high-lead ball screw.

Author Keywords :

high-lead ball screw nuts, new grinding process, surface roughness

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

ELECTRODE TOOL DESIGNING IN THE ECM MACHINING FOR CURVILINEAR SURFACES

Tomasz PACZKOWSKI¹, Jarosław ZDROJEWSKI²,
¹Department of Production Engineering, Faculty of Mechanical Engineering, University Of Technology and Life Sciences in Bydgoszcz
²Department of Digital Electronic, Faculty of Telecommunications and Electrical Engineering, University Of Technology and Life Sciences in Bydgoszcz

Abstract

Electrochemical machining with the use of a tool electrode (ECM.S) is one of the basic and most widely used electrochemical technological operations for machining tools and machine parts. This article presents a method of approximating the surfaces with electrode designing curves, with an assumed two dimensional electrolyte flow model in the inter-electrolyte gap. An example of calculations is also presented.

Author Keywords :

computer simulation, electrochemical machining, electrolyte flow

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

ANALYSIS OF THE WIRE ELECTRICAL DISCHARGE MACHINABILITY OF ROOTS OF STEAM TURBINE BLADES

Dariusz POROŚ¹, Stanisław ZABORSKI¹,
¹ Institute of Production Engineering and Automation, Wrocław University of Technology

Abstract

This paper presents method for the unconventional machining of the blades of steam turbines. Blade material as steel X12Cr13 was chosen into the investigation. Blade failures in gas turbine engines often lead to loss of all downstream stages and can have a dramatic effect on the availability of the turbine engines. Conventional machining of the roots of steam turbine blades causes high temperature and rapid wear of tool which makes machining expensive WEDM is currently regarded among the most popular non-conventional machining. WEDM allows treatment of hard, brittle materials and composite, irrespective of their structure (thin-wall components) and mechanical properties. Submitted work is an analysis of potential impact on the received thickness of heat affected zone by appropriate heat treatment of material prior to WEDM. Such action is intended to eliminate or reduce the initiating impact of any microcracks on the formation of surface defects on the turbine blades roots during operation. The aim of the article is to replace the traditional methods of machining the blades roots by WEDM and thus the elimination of problems such as the need to monitor the tool wear. The presented experimental study was carried out on a modern wire EDM Sodick AQ327L. Investigated were the effects of WEDM of X12Cr13 steel as the Heat Affected Zone, the micro-fractures and surface roughness parameters.

Author Keywords :

turbine blades, heat treatment, WEDM

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

REAL-TIME TOOL CONDITION MONITORING IN MILLING BY MEANS OF CONTROL CHARTS FOR AUTO-CORRELATED DATA

Bianca Maria COLOSIMO¹, Giovanni MORONI¹, Marco GRASSO^2
1Politecnico di Milano, Dipartimento di Meccanica, Via La Masa 34, 20156 Milano, Italy
²MUSP Research Centre, Via Tirotti s/n, Loc. Le Mose, 29122 Piacenza, Italy

Abstract

Real time monitoring of tool condirions and machining processes has been extensively studies in tne last decades, but a wide gap is stiil present between research activities and commercial tools. One of the factors which currently limit the utilization of these systems is the low flexibility of off-the-shelf solutions: in most cases they need dedicated off-line training sessions to acquire the reference patterns and thresholds, and/or the need for several input data to be defined a priori by a human operator. Instead of exploiting off-line learning sessions and a prior defined thresholds, this paper proposes an approach for automatic modelling of a cutting process and real-time monitoring of its stability that is based only on data acquired on-line during the process itself. This approach avoids any a-priori assumption about expected signal patterns, and it is characterized by an innovative implementation of well known Statistical Process Control techniques. In particular, with regard to milling processes, the paper proposes the utilization of cross-correlation coefficient between repeating signal profiles as the feature to be monitored, and an EWMA (Exponentially Weighted Moving Average) control chart for auto-correlated data as monitoring tool.

Author Keywords :

statistical process control, profile monitoring, tool condition monitoring

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

THE INTERNET/INTRANET APPLICATION FOR CUTTING REGIME SETTING

Pavel KOVAČ¹, Marin GOSTIMIROVIĆ¹, Milenko SEKULIĆ¹, Nikola PIŽURICA²,
¹University of Novi Sad, Faculty of Technical Sciences, Department for Production Engineering, Trg D. Obradovica 6, 21000 Novi Sad, pkovac@uns.ac.rs
²Affiliation of the second author

Abstract

In the paper Inter for cutting conditions setting during turning is presented. For this task realization M_yS_ql data base and program language PHP was used. For this task realization M_yS_ql data base and program language PHP was used. This data base is completely free and functions on many operative systems (MS Windows, Linux, FreeBSD ...). Program language PHP has very simple syntax and les experienced users can learn how to use it very quickly As the result of this created was Internet/Intranet application that can be used on Internet also as on own net (Intranet). Application is located on Apache web server.

Author Keywords :

optimal cutting regime, MySql data base, internet

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

COMBINED SYSTEM FOR OFF-LINE OPTIMIZATION AND ADAPTIVE CUTTING FORCE CONTROL

Franc CUS¹, Joze BALIC²,
¹University of Maribor, Faculty of Mechanical Engineering, franc.cus@uni-mb.si22
²University of Maribor, Faculty of Mechanical Engineering, joze.balic@uni-mb.si

Abstract

The choice of manufacturing processes is based on cost, time and precision. A remaining drawback of modern CNC systems is that the machining parameters, such as feed-rate, cutting speed and depth of cut, are still programmed off-line. The machining parameters are usually selected before machining accordin to programmer's experience and machining handbooks. To prevent damage and to avoid machining failure the operating conditions are usually set extremely conservative. As a result, many CNC systems are inefficient and run under the operating conditions that are far from optimal . Even if the machining parameters are optimised off-line by an optimisation algorithm they cannot be adjusted during the machining process. In this paper, a neural adaptiv controller is developed and some simulations and experiments with the neural control strategy are carried out. The results demonstrate the ability of the proposed system to effectively regulate peak forces for cutting conditions commonly encountered in end milling operations.

Author Keywords :

manufacturing processes adaptive cutting force control, milling simulator, neural control strateg off-line optimization

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

ESTABLISHING A BASIS FOR SUSTAINABLE RE-USE OF CUTTING TOOLS THROUGH LASER DECOATING

Paul MATIVENGA¹, Mohamad RAJEMI¹, Sundar MARIMUTHU¹, Lin LI¹, S. YANG², K. COOKE^2
1School of Mechanical, Aerospace and Civil Engineering, The University of Manchester, UK, e-mail: P.Mativenga@manchester.ac.uk
²Teer Coatings Ltd, UK

Abstract

There is an urgent and growing need to reduce the environmental footprints of products and manufacturing processes and to support sustainable material consumption. For engineering applications this implies the need to develop low energy/carbon footprint manufacturing processes tha utilise extended life tooling. In machining, nano-structured coatings can be used to extend service life of cutting tools. However, hard coatings pose a challenge to the re-shaping and re-use of tools. This work investigated the use and re-use of cutting tools by developing selective tool coating removal using laser and conventional chemical de-coating technology. The laser de-coated tools were re-coated and their machining performance was compared to that of chemical de-coated and re-coated tools as well as first generation coated and uncoated tools. The paper presents a comparison of the energy footprints associated with the re-use of tooling. It is concluded that high value tooling can exploit material re-use procedures.

Author Keywords :

reuse, laser, machining

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

MONITORING SYSTEM FOR HIGH SPEED WOOD MACHINING PROCESSES

Hans-Werner HOFFMEISTER¹, Martin LUIG¹, Ronald WITTMER¹, Bernd-Christian SCHULLER¹, Henning STRAUSS¹, Saskia BIEHL^2
1Institute of Machine Tools Aand Production Technology (TWF), Braunschweig, Germany
²Fraunhofer-Institute for Surface Engineering and Thin Films (FhG IST), Braunschweig, Germany

Abstract

The improvement of product quality as well as the increase of production efficiency is inevitable in modern manufacturing processes. In this regard an increased cutting speed causes dangerous process situations in respect to operator safety and machine damage. In addition to that wood working machines generally do not use process monitoring systems, e. g. tool breakage monitoring. The aim of this project was the development of a process monitoring system to increase safety in wood working processes. Therefore, the Institute of Machine Tools and Production Technology (IWF) and the Fraunhofer-Institute of Surface Engineering and Thin Films (FhG IST) developed a sensor-integrated tool holder, which is able to detect clamping forces and unbalances during the process. The hollow shank taper 'HSK-63-F' was chosen as tool holder as it is used in the majority of applications in wood working processes. The clamping and balance conditions are measured by an embedded piezo-resistive thin film sensor at the planar contact surface. To ensure a contact-free signal transmission a telemetric system was used. The interaction between this monitoring system and the machine control automatically activates an emergency stop. Hence, a system was developed which significantly increases the process safety during the run-up and the idle speed phase of the spindle.

Author Keywords :

process monitoring, tool holder, piezoresistive thin film sensor

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

DESIGN AND DYNAMIC CHARACTERIZATION OF COMPOSITE MATERIAL DAMPERS FOR PARTING-OFF TOOLS

Lorenzo DAGHINI¹, Andreas ARCHENTI¹, Cornel Mihai NICOLESCU^1
1Royal Institute of Technology, KTH Production Engineering, Stockholm, Sweden

Abstract

This paper introduces a novel design for parting-off tools and the method to characterize their performance. 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 tool has been characterized by the dynamic characteristics criterion, i.e. frequency and damping ratio, of the machining system, as well as the roughness of the machined surface criterion. This paper demonstrates a new model-based method for characterizing the machining system dynamic properties, applied, in this sThe presented mathematical model of the machining system is based on the data recorded by a microphone during operational conditions. In this way, a step beyond the classical method of analyzing the dynamics of a machining system, which separately identifies the structural and process parameters is taken. The analyses together with the experimental results proved that the parting-off tool was able to machine over a wide range of cutting parameters. It was found that the limiting factor for increasing cutting parameters is not the damping capability of the tool but the tool clamping system stiffness and the workholding system dynamic properties. This implies that, in order to further optimize the machining performance, it is vital to take consideration not only the tool-clamp-turret system but the whole machining system.

Author Keywords :

damping, parting-off, model-based identification, stability, operational damping ratio, operational frequencies

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

INFLUENCE OF APPLICATION OF SPECIAL CASTING COMPOUND ON DYNAMIC CHARACTERISTICS OF THE GUIDEWAY SYSTEM

Bartosz POWAŁKA¹, Tomasz OKULIK¹,
¹ West Pomerania Universitet of Technology, Szczecin, Poland

Abstract

The work presents a new technology for the assembly of ball guideway systems which involves the use of a thin layer of special casting compound (EPY resin) used mainly for stable seating of machinery, especially on steel or concrete foundations. The paper presents results of simulation investigations. Simulation model was built using results of static tests. The results of simulation dynamic tests in the form of frequency response functions are shown. Experimentally supported simulation research presented in the work indicates that the use of EPY resin between the guide rail and the bed of the machine tool positively influences the dynamics of the system. The comparison of the new solution with the one used so far was performed on the basis of a guideway combination consisting of a body and a milling table. The dynamics was compared with the use of a frequency response function obtained using an impulse test. The proposed solutions are characterized by higher dynamic stiffness, which may directly influence the precision of the machined surfaces.

Author Keywords :

EPY resin, dynamics, ball rail system, guideways

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

MODERN MACHINE TOOLS IN APPLICATION TO ADVANCED AEROSPACE COMPONENTS MANUFACTURING

Grzegorz RADKOWSKI¹, Grzegorz SZYSZKA¹,
¹WSK PZL-Rzeszów S.A.

Abstract

The article describes general characteristics of components produced by WSK "PZL-Rzeszow" S.A. (WSK) and their influence on machine tool's technical requirements and special accessories defined during the procurement process of new machining center or lathe. It shortly presents the investment process in new machine tool and a new product implementation path. A point on CAD/CAM and CNC systems existing in WSK and some specific aspects concerning such software is also mentioned. Maintenance challenges have also been pointed to based on WSK's experience.

Author Keywords :

advanced aerospace structure, machine tool selection, software, service

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

TOOL TECHNOLOGY TO REDUCE CUTTING HEAT GENERATION AND ITS INFLUENCES

Ye Htut SOE¹, Ikuo TANABE¹, Tetsuro IYAMA ², Thang Binh HOANG^3
1Nagaoka University of Technology, Dept. of Information Science and Control Engineering, Japan
²Nagaoka University of Technology, Dept. of Mechanical Engineering, Japan ³Nagaoka University of Technology, Educational affairs section, Mechanics and Machinery Group, Japan

Abstract

Recently, the use of hard materials has increased for product quality and safety reasons. Consequently, the cutting conditions for these materials become severe resulting in shorter tool life due to higher cutting temperature. In this paper, tool technology to reduce heat generation and its influences during cutting is investigated and evaluated experimentally. The approach for reducing cutting heat generation is considered by changing the tool geometry and reducing the frictiona coefficient between tool and chip. The approach for reducing influence of the generated heat is application of a therma insulator (coating) on the tool material having high thermal conductivity and heat-resistance. The turning process is used in the experiments. The thermal influences are made clear by each experimental parameter and then, the optimum tool parameters were considered from experimental results. It is concluded that; (1) When rake angle was 15 degree, temperature rise on the tool was smallest. (2) Temperature rise on the tools coated with TiAlN or DLC (Diamond Like Carbon) were reduced from 20 % to 30 %. (3) Several tool materials were quantitatively evaluated by consideration of the thermal conductivity, as well as thermal dependency of their hardness.

Author Keywords :

tool temperature, tool life, tool material heat generation, frictional coefficient

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

SIMULATION OF SINGLE GRAIN CUTTING USING SPH METHOD

Niklaus RUTTIMANN¹, Sebastian BUHL², Konrad WEGENER^1
1IWF - Institute of Machine Tools and Manufacturing, ETH Zuerich
²Empa - Swiss Federal Laboratories for Materials Science and Technology

Abstract

So-called Engineered Grinding Tools (EGT) have been developed in order to satisfy the industry's demand for more efficient and cost-effective grinding tools, which differ from classic grinding tools by placing and brazing single abrasive grains in a predefined pattern onto the grinding tool body. Single grain cutting simulations form an important part towards an advanced understanding of the engineered grinding process. Cutting simulations with FE Methods encounter problems arising from large deformation and material separation. These can be overcome using meshless methods. In this work, a Smooth Particle Hydrodynamics (SPH) Method is used to model the single diamond grain cutting, which can be used as the basis process for physical simulation of the grinding process. As results the influence of the grain geometry, grain orientation and grain placement on the cutting forces, the burr generation and the chip removal rate are presented. It is shown that the cutting forces for a given grain geometry as well as the burr generation are heavily influenced by the orientation of the minor and the main cutting faces. Also cutting in material being work hardened by preceding grains, is simulated in order to be able to synthesize the grinding process from single grain cutting.

Author Keywords :

single grain cutting, engineered grinding tools, smooth particle hydrodynamics

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

CHATTER IN MILLING OF COMPOSITES: SIMULATIONS AND DIAGNOSTIC

Rafal RUSINEK^1
1Lublin University of Technology, Nadbystrzycka 36 st. 20-618 Lublin, Poland. E:mail: r.rusinek@pollub.pl

Abstract

The study focuses on the problem of milling stability, specially dedicated for materials with heterogeneous mechanical properties like composite materials where specific cutting force depends on fibre location and orientation. Classical model of regenerative milling is completed by adding a harmonic function which represents a change of specific cutting force. Finally, an influence of specific cutting force modulation on process stability is presented and vibrations analysis is performed.

Author Keywords :

milling process, chatter regenerative model

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

ADJUSTMENT AND IMPLEMENTATION OF CAD/CAM SYSTEMS BEING USED IN POLISH AVIATION INDUSTRY

Włodzimierz ADAMSKI^1
1Rzeszow University of Technology, Poland

Abstract

This paper describes the detailed methods and process of creating MBD model (Model Based Definition) - presently used in aviation and automotive industry. Existing formats of the Authority dataset have been presented. Using CAD/CAM systems requires introduction of full control of all software used during entire manufacturing process. To maintain DPD (Digital Product Definition) data configuration, controlling production hardware and tools, all media created on the DPD data need to include dataset clear name, revisions level and any other additional unique client identification. There are two methods of reliable verification of data translation or transmission among reality by the use of computer hardware and software. The purpose of this paper is to present new rules of working with CAD/CAM systems in modern enterprises using manufacturing technologies of XXIst century.

Author Keywords :

model based definition, design, methods

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

FORESIGHT OF MATERIALS SURFACE ENGINEERING AS A TOOL STIMULATING SUSTAINABLE DEVELOPMENT AND TO INCREASE THE QUALITY OF TECHNOLOGY

Anna DOBRZAŃSKA-DANIKIEWICZ^1
1Institute of Engineering Processes Automation and Integrated Manufacturing Systems, Silesian University of Technology, ul.Konarskiego 18a, 44-100 Gliwice, Poland, E-mail address: anna.dobrzanska-danikiewicz@polsl

Abstract

Technological e-foresight on the subject of "Foresight of surface properties formation leading technologies of engineering materials and biomaterials. FORSURF" aims to identify the priority innovative technologies and strategic research trends concerning the materials surface engineering. For the purposes of conducting e-foresight, the methodology of computer aided foresight integrated researches management has been used. Conducted foresight research makes an effort to meet the market expectations and its implementation will facilitate the formulation of development strategy for small and medium-sized enterprises. The identification of leading technologies and presenting them in the form of information sheets will allow the economic representatives to be presented with those of them which have the greatest chance of contributing to the country's sustainable development. It will also provide the possibility to determin the scale of the described phenomena and select those technologies which are best for the effective implementation in the industry in respect of their advancement and "quality-price" relationship. The achievement of foresight objectives will contribute, in the long-term, to the development of knowledge-based economy, statistical increase in the quality of technologies implemented in the industry, and sustainable development.

Author Keywords :

E-foresight, surface engineering, knowledge-based economy

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

THE COMPUTER SYSTEM FOR DESIGN OF THE TIG WELDING OPERATION

Konrad PERZYŃSKI¹, Łukasz RAUCH¹, Danuta SZELIGA¹, Jacek ROŃDA¹, Maciej PIETRZYK^1
1Akademia Gorniczo-Hutnicza, al. Mickiewicza 30, 30-059 Krakow, Poland

Abstract

The paper presents a computer system dedicated to simulation of the TIG welding process. The main functionality of the system, i.e. support and facilitation of design of welding technology, will be obtained through flexible combination of the modular architecture of the numerical library and optimization procedures. The TIG heat source model and a structure of a computer system is described. The analysis of phenomena occurring in welded material is important for a selection of optimal process parameters. This contributes to improvement of the product reliability. Particular attention is focused on the development of a reliable numerical model of TIG welding for the linear joint. All process parameters are identified and gathered together in one complex database. The phenomenological heat source model is validated by comparison of evaluated temperatures in a discrete pint with experimental measurements. The validated heat source model is used as the main part of a computer system supporting TIG welding. The architecture of this computer system as well as details of implementation are described in the paper.

Author Keywords :

weld, gas tungsten arc, aluminium, FEM

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

COGNITION-BASED SELF-OPTIMISATION OF AN AUTOMOTIVE REAR-AXLE-DRIVE PRODUCTION PROCESS

Robert SCHMITT¹, Christian NIGGEMANN¹, Mario ISERMANN², Matthis LAASS¹, Nico MATUSCHEK^3
1Laboratory for Machine Tools and Production Engineering, RWTH Aachen University, Germany
²Fraunhofer Institute for Production Technology IPT, Aachen, Germany
³BMW Group, Dingolfing, Germany

Abstract

The production of automotive rear-axle drives is a complex process. This is due to many involved process steps, factors and interdependencies between processes, materials, means of production and individuals acting in this environment. In general their effect on product variations is not fully comprehended. Hence, a holistic analytical model is only possible in parts of the production. In this paper a modular approach is presented to make the production more flexible and enable it to react faster on product variations. This is achieved by a Cognitive Production System (CPS), which is based on accumulating, storing and processing of process knowledge so that it can be applied to similar cases. Through the combination and interaction of Cognitive Tolerance Matching (CTM) and Agent-based Systems the performance of the CPS is enhanced. The work discusses the set-up of such a CPS for the production of automotive rear-axle-drives with the focus on the failure state agent.

Author Keywords :

Agent-Based Systems, cognition self-optimisation, rear-axle-drive

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

CONTROL OF TOOL TEMPERATURE USING NEURAL NETWORK FOR MACHINING MATERIALS WITH LOW THERMAL CONDUCTIVITY

Ye Htut SOE¹, Ikuo TANABE², Tetsuro IYAMA³, Yohtaro ABE^2
1Nagaoka University of Technology, Dept. of Information Science and Control Engineering, Japan
²Nagaoka University of Technology, Dept. of Mechanical Engineering, Japan
³Nagaoka University of Technology, Educational affairs section, Mechanics and Machinery Group, Japan

Abstract

Recently titanium and nickel alloys have become pre-eminent for aeronautic and astronautic parts. Since these cutting and becomes severely demaged. It is important to control cutting tool temperature. In this paper,the control system of tool tip temperature using inverse analysis of neural network for machining these materials was developed and evaluated. The neural network between cutting conditions and tool temperature was firstly created by a set of teaching data. Then, a mathematical model using algebra was developed. Cutting speed was selected as parameter to be controlled in reducing tool temperature. The relationship between the optimum cutting speed and cutting time was calculated with the inverse analysis of neural network by pre-reading of NC program before cutting. The tool temperature can be maintained at the desired value. The developed system is evaluated by the expaeriments using the turning process and workpiece of Ti6Al4V. From the results, it is concluded that; (1) Tool tip temperature can be controlled by using the proposed inverse analysis of the neural network, (2) CThe cutting tool life can be maintained by this method, for cutting materials with low thermal conductivity.

Author Keywords :

titanium alloy, nickel alloy, neural network, tool, tool temperature

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

DEVELOPMENT OF BILATERAL CONTROL SYSTEM FOR PROCESS MACHINING SUBJECT TO CHANGING CUTTING CONDITIONS

Tsuginobu OSADA¹ Yano KEN'ICHI¹, M. S. FOFANA^2
1Mechatronics Laboratory, Department of Mechanical Engineering, Faculty of Engineering Mie University, 1577 Kurimamachiya-cho, Tsu-city, 514-8507, Japan
²MIRAD Laboratory, Mechanical, Robotics and Manufacturing Engineering Department, Worcester Polytechnic Institute Worcester, MA 01609, USA

Abstract

Finishing processes such as deburring are performed on a wide variety of products in various quantities by machinists on a piece-by-piece basis in order to improve surface finish. Deburring is a major contributor to time and cost of the improvement of the surface finish. During deburring, the intended quality of the surface finish is very much dependent on the operator's skills. This work is concerned with understanding and interpreting how a bilateral robot can assist the deburring process. We propose a control method based on a machining model that is made up of several components, including the cutting tool, spindle speed, feedrate of the tool and other important constituent elements of the machining system. Machining operations are carried out for selected cutting conditions. A haptic robot is directly connected to the machine-tool and the operator. The motion of the haptic robot is controlled automatically under machining conditions in which it is possible to achieve highly accurate surface finish. The force feedback from the haptic robot influences the continuous adjustments made by the machining operator. Mathematical equations for the haptic interaction between the robot and process machining, involving time delays, are established. For specific range of cutting conditions, the regimes wherein the bilateral control system enhances the surface finish of the work piece in a sustained way are located. The regimes and effectiveness of the control system are quantified experimentally.

Author Keywords :

man-machine system, bilateral control, machining robot

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

METHODS OF MACHINE TOOL ERROR COMPENSATION

Paweł TUREK¹, Jerzy JĘDRZEJEWSKI¹, Wojciech MODRZYCKI^1
1 Institute of Production Engineering and Automation, Wroclaw University of Technology, Poland

Abstract

The most important tendencies in the development of modern machine tools are pointed out, including the improvement of their design and development of error compensation methods. An overview of the most popular and useful error compensation methods for machine tools is presented. Based on examples, the effectiveness and limitations of each method are discussed. An integrated 5-axis machine tool behaviour model is presented, which assists in the elaboration of an error model required for the compensation purposes.

Author Keywords :

machine tool, errors compensation methods

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

MODELLING THERMAL DEFORMATION OF TILTING ROTARY TABLE WITH DIRECT DRIVE SYSTEM

Andrzej BŁAŻEJEWSKI¹, Wojciech KWAŚNY¹,Jerzy JĘDRZEJEWSKI¹, Tae-Weon GIM^2
1 Institute of Production Engineering and Automation, Wroclaw University of Technology, Poland
²DOOSAN Infracore Corporation, Korea

Abstract

Mathematical models representing power losses in tilting rotary tables with a direct drive system (increasingly often used in CNC machine tools) are presented. The process of creating an FEM model for computing the heating up and thermal deformation of tilting rotary tables is described. A simple way of verifying the FEM model on the basis of motor catalogue specifications is provided. Exemplary results of computations and thermal analyses carried out for a tilting rotary table with a synchronized two-sided direct drive system are reported.

Author Keywords :

machine tool, tilting rotary table, thermal deformation, model

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

THERMAL MODEL OF THE SPINDLE DRIVE STRUCTURE

Zdzisław WINIARSKI¹, Zbigniew KOWAL¹,Wojciech KWAŚNY¹, Jae-Yong HA^2
1 Institute of Production Engineering and Automation, Wroclaw University of Technology, Poland
²DOOSAN Infracore Corporation, Korea

Abstract

A computation system dedicated for machine tool spindle drives is presented which integrates a FDM model with a FEM model. Modelling of heat exchange through coolers are discussed, as well as modelling of heat exchange between cooling-lubricating oil and gear transmissions, shafts and headstock walls. In modelling of heat exchange inside headstock, the use of additional elements - type "Fluid" and "Air" - is proposed. Sample modelling results are presented concerning a headstock from a drilling-milling machine tool for machining with high loads and are compared with experimental data.

Author Keywords :

machine tool, spindle unit temperature, thermal deformations, model

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

INTEGRATION OF VISION BASED IMAGE PROCESSING FOR MULTI-AXIS CNC MACHINE TOOL SAFE AND EFFICIENT TRAJECTORY GENERATION AND COLLISION AVOIDANCE

Rafiq AHMAD¹, Stephane TICHADOU², Jean-Yves HASCOET^2
1IRCCyN, Ecole centrale Nantes, Rafiq.Ahmad@irccyn.ec-nantes.fr, Tel.: ++ 33 2 40 37 69 62
²Ecole centrale Nantes, Stephane.Tichadou@irccyn.ec-nantes.fr, Tel.: ++ 33 2 40 37 69 06
²Ecole centrale Nantes, Jean-Yves.Hascoet@irccyn.ec-nantes.fr, Tel.: ++ 33 2 40 37 69 49

Abstract

Demand of high speed production not only increases the complexity of today's CNC process, but also increases the risks and possibility of collision because of the difference between real (machining) and virtual scenes (CAD/CAM process). Idea here is to make this process more intelligent by processing image taken from the real or virtual machine scenes. Identify objects (already known in the CAD database), obtain safe and efficient trajectories that will modify the previous known trajectories from the CAM systems and will be used finally in real machining environments. This work more focuses to improve trajectory generation, collision avoidance and communication in CAD/CAM systems by image processing technique. Safe and Efficient Trajectory (SET) algorithm for point trajectory is discussed along with its extended version for object trajectory known as Rectangular Enveloped object Safe and Efficient Trajectory (RESET) algorithm that will perfectly generate safe un-functional trajectories [3] for multi-axis machine tool envelop. Meanwhile scene objects are detected and identified by image processing tool while trajectory and setup is optimized and improved accordingly in order to avoid collision. This generated trajectory can be used for setup correction before and after production or for "real times/online" production. Finally work has been validated through real and virtual machine scene images.

Author Keywords :

trajectory generation, object detection and identification, multi-axis machines, collision avoidance

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

ADAPTIVE CONTROL OF ECM CURVILINEAR SURFACES

Tomasz PACZKOWSKI¹, Jarosław ZDROJEWSKI^2
1Departament of Production Eng., Faculty of Mechanical Eng., University of Technology and Life Science in Bydgoszcz, Poland
²Departament of Digital Electronic of Telecommmunication and Electrical Eng., University of Technology and Life Science in Bydgoszcz, Poland

Abstract

Electrochemical machining (ECM) of curvilinear surfaces is one of the most basic and widely spread among electrochemical technology procedures for machine and tool parts. Constant parameters for preset machining time are hard to determine in this technology. This article presents a method of creating controlling code for ECM processing for which machining parameters changing over time are determined in a computer simulation of the process. An example of carrying out calculations, leading to determining process controlling code for preset electrode surfaces, is also presented, as well as the outcome of experimental verification.

Author Keywords :

computer simulation, electrochemical machining, adaptive control

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

COMBINATION OF END-OF-LIFE STRATEGIES FOR EXTENSION OF INDUSTRIAL EQUIPMENT LIFE CYCLE

Viktoria BASHKITE¹, Vadim MOSEICHUK¹, Tatyana KARAULOVA^1
1Tallinn Technical University, Ehitajate tee 5, 19086, Tallinn, Estonia, tatjana.karaulova@ttu.ee

Abstract

As many manufacturing companies are changing their production philosophies from a traditional focus on the manufacturing of the physical product towards a focus on the life cycle of the physical product, it is becoming important to engineer product's life cycle. Even more, many industrial researchers of the last decade see product's life cycle prolonging activities as a business opportunity both in economical and environmental ways. As a result, more focus is now put on the use phase and end-of-life phase, including maintenance and remanufacturing. The analysis of current end-of-life practices identifies significant improvements to product design that reduce the impact of manufactured goods on the environment as whole. Life cycle engineering and product take-back is a routine for many large industries and corporations nowadays, but, it is still a big challenge for a small and medium companies. In context of end-of-life strategies implementation, there is a very little experience for smaller firms, and results are often controversial. This paper will touch material processing equipment end-of-life strategies combination perspectives, real-life implementation of them, benefits and consequences. The case study is made on a basis of a lorry that will be transferred into spoil mixing plant.

Author Keywords :

environmental conscious manufacturing, green design, remanufacturing, end-of-life strategy, material processing equipment

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

AXIS LOCATION AND SCALE FACTORS ESTIMATION FOR THREE-AXIS MACHINES FROM PERIODIC PERFORMANCE CHECKS WITH LASER DISTANCE MEASUREMENTS - RISKS AND OPPORTUNITIES

Abdelhak NAFI¹, Anna ŁOŚ¹, J.R.R. MAYER^1
1Département de génie mécanique, section fabrication, École Polytechnique, C.P. 6079, succ. Centre-ville Montréal (Qc), CANADA H3C 3A7

Abstract

Users of coordinate measuring machine and large gantry machines need to ensure the volumetric performance of their machines in order to inspect, or machine, mechanical parts with precision. In the case of CMMs, the ASME B89.4.10360.2-2008 document imposes seven directions for a volumetric check. These directions offer some redundancy for axis location (out-of-squarenesses) and scale factor estimation. The paper looks at the opportunity of using the data for immediate machine correction and the risks involved. In particular, the fact of using test data for calibration and verification, the potential contamination from non-modelled motion errors and the representativity of the estimated parameters are considered. Experimental results obtained using laser interferometry on a LEGEX CMMs are used to present the main concepts.

Author Keywords :

CMM, calibration, performance, diagnostic

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

MODELLING OF VIBRATION WITH ABSORBER

Jiří VONDŘICH¹, Evžen THÖNDEL¹, Slavomír JIRKŮ^1
1Czech Technical University in Prague, Faculty of Electrical Engineering, Department of Electric drives and Traction, Technická 2,166 27 Prague 6, Czech republic, vondrich@fel.cvut.cz, thondee@efel.cvut.cz, jirku@fel.cvut.cz

Abstract

Machine vibration occurs as a result of unbalanced revolving masses, loading forces and moments, starting and coasting of driving motors and other effects. We try to eliminate these undesirable vibrations by suitable mounting of the mechanical system. Another possibility of suppression of the vibration machine is to use an absorber. A model of a vibration mechanical system with a vibration absorber is presented in the paper. The model consists of a fixed-end vibrating beam with primary vibrating mass M and with stiffness K and damping B. The harmonic force F with frequency ? and amplitude A acts on the primary mass M as well as on the beam with stiffness k and damping b, where the secondary mass m of the absorber is mounted. The task of the absorber is to minimize the movement of the mass M. A model (Fig. 1) has two degrees of freedom X and x. Two equations describe the movement of the primary mass M and the secondary mass m of the absorber. The model is solved first numerically by using Simulink. In numerical solution it is possible to set up parameters of the mechanical system with respect to the vibration reduction. According to the mechanical requirements for the mechanical system (output trajectory, velocity, forces and torques acting on the individual parts of the system), it is also possible to design input parameters (driving torques and other parameters of the mechanical system). A experimental model will be designed in order to verify results, where a voice-coil will be used as the actuator of the force F Numerical and experimental model allows changing parameters i.e. masses M and m, length L and l of the beams and frequency ? of the excitation force F. The results from the numerical solution are then possible to compare with the measured values of the experimental model. It is assumed that the experimental model will be equipped with accelerometers enabling the measuring of vibration, which will be placed on the masses M and m.

Author Keywords :

mumerical modelling, Simulink, vibration, machine, absorber

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2010, Poland

STATIC AND DYNAMIC STIFFNESS OF CNC MACHINE TOOL SERVO DRIVES

Zoran PANDILOV¹, Vladimir DUKOVSKI^1
1University "Sv. Kiril i Metodij"-Skopje, Faculty of Mechanical Engineering, Karpos II b.b., P.O.Box 464, MK-1000, Skopje, Republic of MACEDONIA, Tel.: 389 2 3099 259 Fax: 389 2 3099 298 E-mail: panzo@mf.edu.mk

Abstract

In this paper a model for the servo drive system with disturbance forces is given. Static and dynamic stiffness for the proposed model is analyzed. An equation for analytical calculation of the static stiffness is given. Correctness of the proposed equation is experimentally verified. Simulation of the influence of some parameters on the static and dynamic servo drive system stiffness is performed with simulation program MATLAB & SIMULINK.

Author Keywords :

static stiffness, dynamic stiffness, CNC machine tool, servo drive