CONTENTS

JOURNAL OF MACHINE ENGINEERING

o article: Minor Surface Finishing of Hardened Die Steel by Hich-Power Ultrasonic Elliptical Vibration Cutting (Jung H., Shamoto E., Ueyama T., Hamada S., Liangji XU), pp. 5-14
o article: Influence of Surface Textures Produced by Finishing Operations on Their Functional Properties (Grzesik W.,), pp. 15-23
o article: Areal Field and Fractal Based Characterization of Hard Surfaces Produced by Different Machining Operations (Zak K.), pp. 24-32
o article: Calibration Performance Investigation of an Uncalibrated Indigenous Artefact Probing for Five-Axis Machine Tool (Rachman Md. M., Mayer R.), pp. 33-42
o article: Modelling and Optimization of Machine Tools on Foundations (Novotny L., Sindler J., Fiala S., Sveda J.), pp. 43-56
o article: Robot Manipulator Usage for Measurement in Production Areas (Kuts V., Tahemaa T., Otto T., Sarkans M., Lend H.), pp. 57-67
o article: Investigation of Operational Properties of Wave Transmission (Kosmol J.), pp. 68-78
o article: Productive Machining of Complex Shape Parts (Zabransky V., Vavruska P.), pp. 79-91
o article: Management of Newness in an Assembly System (Schedin J., Svensson-Naradi N., Jackson M., Deleryd M. ) pp. 92-108

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© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

MIRROR SURFACE FINISHING OF HARDENED DIE STEEL BY HIGH-POWER ULTRASONIC ELLIPTICAL VIBRATION CUTTING

Hongjin JUNG¹, Eiji SHAMOTO¹, Takashi UEYAMA², Seiji HAMADA², Liangji XU^3
1Nagoya University, Graduate School of Engineering, Japan
²Taga Electric Co., Ltd., Product Development Department, Japan
³The Boeing Company, Boeing Research & Technology, USA

Abstract

Ultrasonic elliptical vibration cutting has recently been utilized in industry for finishing of various precision parts such as mirror surface finishing and precision micro machining of dies and molds. However, its application has been limited to high-cost ultra-precision machining, where depth of cut is typically in a range from a few micrometers to several tens of micrometers due to power limitation of the vibration device. To expand its application to low-cost mirror surface finishing with ordinary machining facilities, a high-power elliptical vibration device was developed in this research. The elliptical vibration cutting of hardened die steel was examined by applying the developed high-power elliptical vibration device with single crystalline diamond tools. Pick feed was kept to be 0.02 mm to obtain mirror quality surfaces, while depth of cut was increased up to 0.4 mm to verify performance of the high-power elliptical vibration cutting. By analyzing the experimental results, it was clarified that mirror surface finishing of the hardened die steel can be achieved at the large depth of cut with practically acceptable tool life.

Author Keywords :

elliptical vibration cutting,mirror surface finishing,hardened steel

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016, Poland

INFLUENCE OF SURFACE TEXTURES PRODUCED BY FINISHING OPERATIONS ON THEIR FUNCTIONAL PROPERTIES

Wit GRZESIK^1
1Faculty of Mechanical Engineering, Opole University of Technology, Opole, Polandpl

Abstract

This literature survey highlights the possible influences of surface roughness parameters on functional properties of surfaces produced by different finishing operations. The prediction of such functional properties as fatigue, sealing capacity, adhesion, friction, wear and corrosion resistance based on five groups of spatial (S) roughness parameters is overviewed. In contrast, traditional approach based on 2D roughness parameters is provided. Some real 3D surface topographies produced with desired functional properties by finishing cutting and abrasive operations are characterized. This survey confirms the vital role of machined surfaces in the functionality of machine components.

Author Keywords :

machining; surface texture, functional performance

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016, Poland

AREAL FIELD AND FRACTAL BASED CHARACTERIZATION OF HARD SURFACES PRODUCED BY DIFFERENT MACHINING OPERATIONS

Krzysztof ZAK^1
1Faculty of Mechanical Engineering, Opole University of Technology, Opole, Poland

Abstract

The purpose of this study is to compare four surface textures produced by hard turning operations with CBN cutting tools, grinding operations using conventional ceramic and CBN wheels, and ball burnishing using Si3N4 ceramic ball with the Sa parameter of about 0.2 μm. These surfaces are characterized by standardized area field (3D) roughness parameters and non-standardized fractal dimensions. A new approach to the characterization of surface topographies using area-scale fractal analysis is proposed. In particular, some important correlations between surface texture parameters and fractal dimensions are determined and discussed.

Author Keywords :

hard machining, grinding, ball burnishing, surface texture, fractals

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016, Poland

CALIBRATION PERFORMANCE INVESTIGATION OF AN UNCALIBRATED INDIGENOUS ARTEFACT PROBING FOR FIVE-AXIS MACHINE TOOL

Md Mizanur RAHMAN¹, Rene MAYER^1
1Mechanical Engineering Dept., Polytechnique Montréal, Montréal (QC), Canada

Abstract

On machine measurement of artefacts such as single ball, multiple balls or even prismatic shape artefact is gaining popularity for the calibration of five-axis machine tools. However, calibration results can be degraded due to errors from different process variables such as the measurement strategies, rotary axes indexations and artefact dismount and remount cycles. This research investigates the repeatability of uncalibrated indigenous artefact probing and machine tool error parameters calibration against a number of process variables. Uncertainties of the estimated parameters are estimated to quantify the calibration quality.

Author Keywords :

machine tools, robustness,uncertainty, artefact,

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016, Poland

MODELLING AND OPTIMIZATION OF MACHINE TOOLS ON FOUNDATIONS

Lukas NOVOTNY¹, Jaroslav SINDLER¹, Stepan FIALA¹, Jiri SVED^1
1Czech Technical University in Prague, Faculty of Mechanical Engineering, RCMT, Prague, Czech Republic

Abstract

This paper aims to expand existing complex mathematical models of machines in a manner that would respect the influence of their installation on the foundation. For this purpose, a method of modelling and optimization of foundations was developed. It consists of four basic parts: Mathematical modelling of machines, optimization of the number and placement of fixing (levelling) elements, optimization and modelling of the reinforced concrete foundation and modelling of the subsoil with respect to engineering geological conditions. The main optimization criterion is to increase the lowest natural frequency of the machine while reducing the foundation weight (amount of reinforced concrete).The result is a virtual mathematical model of the machine tool, including the influence of its foundation and subsoil. The proposed optimization can be used for designing new machines, machine foundations and the number and distribution of machine levelling elements. This method has been applied and tested on a virtual model of a multi-purpose machining center for workpieces up to 15 tons.

Author Keywords :

machine tools on foundations,modelling and optimization, machine subsoil,fixing elements, concrete foundation

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016, Poland

ROBOT MANIPULATOR USAGE FOR MEASUREMENT IN PRODUCTION AREAS

Vladimir KUTS¹, Toivo TAHEMAA¹, Tauno OTTO¹,Martins SARKANS¹, Henri LEND^1
1Tallinn University of Technology, Department of Machinery, Tallinn, Estonia

Abstract

Measuring and inspection works in production process using laser scanners attached to the robot manipulators are more and more used in different ways and purposes. The aim of this article is to study and analyze the usage of 3D measuring devices attached to the robot manipulator according to determine the range and the purpose of such industrial measurements. Different scanning devices are applied in production areas with varying purposes, such as 3D scanning of the new product, in order to inspect and find defects. Attached to the robot manipulator, scanners or laser measuring devices are able to scan every object in range of a robot, which makes the measuring process very flexible. Several tests with 3D scanners were performed to find out the optimal conditions and configuration for production purpose. As a result, knowledge base suitable for different production areas was developed. Thus, it would be feasible to have a common database to be implemented in different production areas.

Author Keywords :

industrial robot, production engineering, 3D scanning, measuring, inspection, manipulator

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016, Poland

INVESTIGATION OF OPERATIONAL PROPERTIES OF WAVE TRANSMISSION

Jan KOSMOL^1
1 Silesian University of Technology, Department of Machine Technologies, Gliwice, Poland

Abstract

This article describes the structure and operation of the Harmonic Drive wave transmission. The most important operational properties and advantages of such transmissions have been formulated here. The paper presents the results of experiments performed on the transmission, particularly ones pertaining to angular sensitivity, invariability of transmission ratio and precision of positioning. The presented results are connected with the influence of various methods of drive motor operation and diverse motor speeds on the operational properties of the transmission.

Author Keywords :

wave drive, accuracy of positioning

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016, Poland

PRODUCTIVE MACHINING OF COMPLEX SHAPE PARTS

Vaclav ZABRANSKY¹, Petr VAVRUSKA^1
1Czech Technical University in Prague, Faculty of Mechanical Engineering, Department of Production Machines and Equipment, Prague, Czech Republic

Abstract

This paper deals with technological conditions that are achieved during multi-axis milling operations. The work is focused on the improvement of quality and productivity of machining of complex shape parts. The importance of feed-rate analysis during multi-axis machining operations is mentioned. A postprocessor algorithm for correction of relative feed-rate during multi-axis machining operations has been proposed. The postprocessor generates corrected feed-rate for each block of an NC program when a multi-axis interpolation is found. Thanks to this new postprocessor algorithm, better conditions are achieved during multi-axis machining operations and also a shorter time for NC program execution when it is used without the Tool Center Point transformation. Practical benefits and the functionality of the postprocessor algorithm have been tested by machining the blade containing multi-axis tool paths.

Author Keywords :

CNC, postprocessor, feed-rate, optimization

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016, Poland

MANAGEMENT OF NEWNESS IN AN ASSEMBLY SYSTEM

Joel SCHEDIN¹, Natalia SVENSSON HARARI¹, Mats JACKSON¹, Mats DELERYD^1
1Malardalen University, Sweden

Abstract

The need for new products to suit differentiated customer needs and shorter product life-cycles, forces manufacturers to change or modify products and production systems at more frequent intervals. The objective of this paper is to discuss management of newness within assembly system design in the vehicle industry. Based on a case study covering four assembly development projects, a model using the quality concept of "7M" is presented to evaluate the level of newness. The results show that the model provides a promising platform for evaluation of newness.

Author Keywords :

newness, vehicle, quality assembly system design

CONTENTS

JOURNAL OF MACHINE ENGINEERING

o article: Recent Trends in Metal Forming: from Process Simulation and Microstructure Control in Classical Forming Processes to Hybrid CombinationsBetween Forming and Additive Manufacturing (Bambach M.), pp. 5-17
o article: Numerical Evaluation of Gear Ring Behaviour During Various Cooling Conditions (Perzynski K., Madej L., Szajding A., Raga K., Kubiak K., Niechajowicz A., Jaskiewicz K., Gronostajski Z., Pietrzyk M.), pp. 18-26
o article: The Off-Line Computer System for Design of the Hot Rolling and Laminar Cooling Technology for Steel Strips15 (Rauch L.), pp. 27-43
o article: Modification of Heat Treatment Parameters for Pearlite Steel Intended for Cold Plastic Working (Grygiel M.), pp. 44-51
o article: RCAFE Based Numerical Model of Dynamic Recrystallization (Legwand A., Sitko M., Perzynski K., Madej L.), pp. 52-60
o article: Productivity Increase Through Reduced Changeover Time (Karwasz A., Chrabowski P.), pp. 61-70
o article: Comparison of Methods for Adjusting and Controlling the Preload of Angular-Contact Bearings (Turek P., Skoczynski W., Stembalski M.), pp. 71-85
o article: Evaluation of Classification Ability of the Parameters Characterizing Stereometric Properties of Technical Surface (Kacalak W., Rozanski R., Lipinski D.), pp. 86-94

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© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

RECENT TRENDS IN METAL FORMING: FROM PROCESS SIMULATION AND MICROSTRUCTURE CONTROL IN CLASSICAL FORMING PROCESSES TO HYBRID COMBINATIONS BETWEEN FORMING AND ADDITIVE MANUFACTURING

Markus BAMBACH^1
1Brandenburg Technical University, Mechanical Design and Manufacturing, Cottbus-Senftenberg, Germany

Abstract

This paper describes some recent trends in metal forming such as isothermal forging of titanium aluminides and process combinations between metal forming and additive manufacturing. These trends rely on accurate process and material models for process design. Process and material models must hence be able to track the microstructure evolution in complex materials such as titanium aluminides as well as predict the microstructure evolution along process histories with multiple deformation and/or heat input steps. In models for such processes, JMAK-type kinetics for and phase transformation are still common. For processes involving deformation and heat, the accuracy, consistency and limits of JMAK-type models are discussed. It is shown that the consistency of DRX models as well as the stability of model predictions in multi-stage processes require further attention.

Author Keywords :

metal forming, additive manufacturing,microstructure model,recrystallization

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

NUMERICAL EVALUATION OF GEAR RING BEHAVIOR DURING VARIOUS COOLING CONDITIONS

Konrad PERZYNSKI¹, Lukasz MADEJ¹, Artur SZAJDING², Krzysztof RAGA³,Krzysztof KUBIAK⁴,Adam NIECHAJOWICZ⁵,Karol JASKIEWICZ⁵, Zbigniew GRONOSTAJSKI⁵, Maciej PIETRZYK^1
1Department of Applied Computer Science and Modelling, AGH University of Science and Technology, Poland
²Department of Applied Computer Science and Modelling, Departament of Thermal Engineering and Environment Protection, Poland
³Pratt & Whitney Rzeszow S.A., Hetmańska 120 st., 35-078 Rzeszow, Poland
⁴University of Technology, Department of Material Science, Rzeszow, Poland
⁵Wroclaw University of Technology, Department of Forming Process Engineering, Wroclaw, Poland

Abstract

The phase transformation model incorporated via the user subroutines to the commercial finite element software to accurately predict changes occurring during cooling of metallic components is presented in the paper. The cooling process of steel rings used in airplanes was selected as a case study. Particular attention was put on heterogeneities occurring in temperature field, which influence phase transformations and eventually residual stresses. Developed model was used in the present work to evaluate influence of different cooling conditions on ring behaviour.

Author Keywords :

bainitic transformation, martensitic transformation,cooling process,finite element analysis, APDL

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

THE OFF-LINE COMPUTER SYSTEM FOR DESIGN OF THE HOT ROLLING AND LAMINAR COOLING TECHNOLOGY FOR STEEL STRIPS

Lukasz RAUCH^1,3, Krzysztof BZOWSKI¹, Roman KUZIAK⁴, Jacek KITOWSKI^2,3, Maciej PIETRZYK^1,3
1AGH, Department of Applied Computer Science and Modelling, Krakow, Poland
²AGH, Department of Computer Science, Krakow, Poland
³ACK Cyfronet AGH, Krakow, Poland
⁴Institute for Ferrous Metallurgy, Gliwice, Poland

Abstract

The objective of this work was development of the computer system VirtRoll, which allows designing of the arbitrary rolling line and performing numerical simulations using high efficiency hardware architectures. Selection of the mechanical, thermal, microstructural and phase transformation models, which allow decreasing the computing costs while the accuracy of simulations is maintained on the reasonable level, was one of the objectives of the paper. Thus, metamodel was applied in the mechanical part and a simple finite element approach was used in the thermal part of the hot rolling model. Simulations of microstructure evolution in hot rolling and phase transformations during the laminar cooling were based on modified Avrami equation. The system was designed in the client-server architecture, in which client part is in the form of the graphical interface. This interface allows to design of rolling line. The server part is composed of: i) controllers which prepare computing tasks, ii) middleware layer responsible for launching and monitoring of the computing tasks, iii) the layer of numerical computations. Deal.II library dedicated to solve partial differential equations was used for the time step adaptations. All these parts led to short omputing times and additionally allowed parallel solution of the optimization tasks. Simulations of thermal-mechanical-microstructural phenomena

Author Keywords :

optimization, hot rolling, laminar cooling, steel strips, VirtRoll computer system

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

MODIFICATION OF HEAT TREATMENT PARAMETERS FOR PEARLITE STEEL INTENDED FOR COLD PLASTIC WORKING

Dominika GRYGIER^1
1Wrocław University of Technology, Department of Materials Science, Strength and Welding Technology, Wroclaw, Poland

Abstract

One of the problems widely discussed in the relevant literature is the fatigue cracking of pearlite steel subjected to cold plastic working, as well as of that being currently in operation. Studies presented in the work were aimed at selection of the parameters, and mainly the time, of heat treatment operations of pearlite steel enabling obtaining cold drawn wires characterised with better plastic properties and higher fatigue resistance than the products achieved during standard processes. The idea of modification was based at possibility of obtaining steel of the sorbite, which are a mixture of ferrite and dispersion cementite of high degree of coagulation. The structures obtained with this method, as being globular, should be featured with better plastic properties than the lamellar structures created during standard diffusion transformation of austenite. In addition the discussed change was to enable decreasing the total surface of interphase boundaries at which the highest delaminations of structure were observed, regardless of whether the cause of the change resulted from presence of non-metallic inclusions or pile-up of dislocations.

Author Keywords :

drawing, pearlite, cementite, coagulation, tempering

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

RCAFE BASED NUMERICAL MODEL OF DYNAMIC RECRYSTALLIZATION

Adam LEGWAND¹, Mateusz SITKO¹, Konrad PERZYNSKI¹, Lukasz MADEJ^1
1AGH University of Science and Technology, Department of Applied Computer Science and Modelling, Krakow, Poland

Abstract

The main goal of the paper is dedicated to proper arrangement of the Finite Element (FE) and Random Cellular Automata (RCA) methods in order to develop numerical model of dynamic recrystallization (DRX) and therefore to simulate microstructure morphology changes during plastic deformation at elevated temperatures. In the approach, Finite Element solver provides information on equivalent stress and strain fields after subsequent time steps. Then these data are transferred to RCA model, which is responsible for evaluation of corresponding microstructure morphology evolution and dislocation density changes. Finally, information from the CA part is send back to the FE solver as an input for the next time step. As a result, a fully coupled RCAFE model to simulate progress of DRX is established. The present paper is directly focused on development of algorithms and methods to transfer input/output data between both FE and RCA models. The developed communication protocol is based on the Abaqus VUMAT subroutine. Examples of obtained results from the developed model are also presented to highlight its potential.

Author Keywords :

cellular automata, RCAFE, recrystallization

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

PRODUCTIVITY INCREASE THROUGH REDUCED CHANGEOVER TIME

Anna KARWASZ¹, Przemyslaw CHABOWSKI^1
1Poznan University of Technology, Department of Management and Production Engineering, Poznan, Poland

Abstract

The authors of this paper present the stages of SMED method implementation and standardization of jobs on the example of a company in the metal industry. Particular emphasis is placed on the analysis of the lathe socket, focusing on its standardization and the manner and times of changeover. The work described here is an example of introducing new solutions and improving the changeover process. The summary describes the key results of the improvements, resulting in improved availability of equipment, which in turn translates into increased productivity.

Author Keywords :

Poznan University of Technology, Department of Management and Production Engineering, Poznan, Poland

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

COMPARISON OF METHODS FOR ADJUSTING AND CONTROLLING THE PRELOAD OF ANGULAR-CONTACT BEARINGS

Pawel TUREKk¹, Waclaw SKOCZYNSKI¹, Marek STEMBALSKI^1
1Wroclaw University of Technology, Department of Machine Tools and Mechanical Technologies, Wroclaw, Poland

Abstract

The effect of preload on the operating conditions of angular-contact bearings is described. The interdependences occurring during mutual displacements of bearing rings at different bearing contact angles are discussed. The criteria of the classification into low-speed and high-speed angular-contact bearings are presented. Selected methods of preloading angular-contact bearings are compared and discussed. Their advantages and disadvantages with regard to the active control and adjustment of the bearing system during its operation are presented. The structure of a developed test stand with a spindle assembly is described. Preliminary measurements of the behaviour of the spindle assembly during operation are reported. Conclusions are drawn and the direction for further research is indicated.

Author Keywords :

preload, angular-contact bearings,machine tool

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

EVALUATION OF CLASSIFICATION ABILITY OF THE PARAMETERS CHARACTERIZING STEREOMETRIC PROPERTIES OF TECHNICAL SURFACES

Wojciech KACALAK¹, Rafal ROZANSKI², Dariusz LIPINSKI^1
1Koszalin University of Technology, Faculty of Mechanical Engineering, Koszalin, Poland
²The Jacob of Paradyż University of Applied Sciences in Gorzów Wielkopolski, Technical Department, Gorzów Wielkopolski, Poland

Abstract

The analysis of classification ability of the parameters used for the description of surfaces formed during the processes of technological processing constitutes important issue in the surface layer metrology. To investigate the classification ability, variance and geometric mean of the ordered differences of the parameter value. The study compares behaviour of both indices for different distributions of ordered differences of the parameter value. Moreover, the relationship between bot indices and influence of the number of minor differences of the parameter value on the value of variance and geometric mean.

Author Keywords :

surface geometric structure,parameter classification ability

CONTENTS

JOURNAL OF MACHINE ENGINEERING

o article: Simulation Aided Design of Intelligent Machine Tool Components (Mohring H.Ch., Wiederkehr P., Leopold M., Nguyen Le T., Hense R., Siebrecht T.), pp. 5-33
o article: Modelling of the Coordinate Measuring Systems Accuracy (Sladek J., Gaska A.), pp. 34-46
o article: Identification of Dynamic Cutting Force Coefficients by Direct Measurement of Cutting Forces During Vibratory Cutting (Jemielniak K., Nejman M., Sniegulska-Gradzka D.), pp. 47-57
o article: Analysis of Mechanical Characteristics of Face Milling Process of Ti6Al4V Alloy Using Experimental and Simulation Data (Nieslony P., Grzesik W., Bartoszuk M., Habrat W.), pp. 58-66
o article: Investigation of Sequential Machining Processes in Terms of Power Consumption and Surface Quality (Chudy R., Grzesik W.), pp. 67-74
o article: Measuring the Dynamic Twisting Behaviour of Saw Blades in the Kerf During the Sawing Process (Albrecht D., Stehle T.) , pp. 75-87
o article: Implementation and Demonstration of Characteristic Diagram as well as Structure Model Based Correction of Thermo-Elastic Tool Center Point Displacements (Putz M., Ihlenfeldt S., Kauschinger B., Naumann Ch., Thiem X., Riedel M.), pp. 88-101
o article: System Dynamics as a Decision Support System for Machine Tool Selection (Adane T.F., Nicolescu M.), pp. 102-125
o article: Process Factors of Impact on OEE for Lathes for Machining of Wheelset (Stryczek R., Szczepka W.), pp. 126-140

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© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

SIMULATION AIDED DESIGN OF INTELLIGENT MACHINE TOOL COMPONENTS

H. Christian MOHRING¹, Petra WIEDERKEHR², Mathias LEOPOLD¹, Le Trung NGUYEN¹, Rouven HENSE², Tobias SIEBRECHT^2
1Otto-von-Guericke Univ. Magdeburg, Inst. of Manufacturing Technology and Quality Management (IFQ), Germany
²TU Dortmund University, Institute of Machining Technology (ISF), Germany

Abstract

By integrating sensors and actuators, intelligent machine tool components can be realized, which allow the monitoring of machining processes and machine tool states and an active influencing of process conditions. In the design and layout of these intelligent machine tool components, their mechanical structure and the functional performance of the sensor and actuator sub-systems have to be optimized. As an example, a sensor and actuator integrated fixture system for clamping large but sensitive aerospace structural parts is presented here. In order to investigate the major influences of design approaches on the behaviour of the workpiece and fixture, especially with respect to vibrations and process stability during milling, multiple test rigs and prototypes for basic analyses and machining tests were developed and realized. Experimental and Finite Element Analysis (FEA) results are presented and discussed. Process simulations were conducted taking the dynamic behaviour of the clamped workpiece at different processing steps into account. This simulation can be used for predicting the limits of the process stability. An approach of sensor and actuator integration is described and test results are shown. The paper introduces a principle design and layout methodology for similar intelligent machine tool components.

Author Keywords :

characteristic diagram based correction, structure model based correction, thermo-elastic deformation, online enabled TCP correction machine tool, intelligent component, process simulation, layout methodology

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

MODELLING OF THE COORDINATE MEASURING SYSTEMS ACCURACY

H. Jerzy SLADEK¹, Adam GASKA^1
1Cracow University of Technology, Laboratory of Coordinate Metrology, Cracow, Poland

Abstract

Coordinate metrology determines nowadays the relevant directions of development in automated measuring systems and quality management in the field of machine industry. The essential problem of coordinate measuring technique application is the issue of accuracy assessment of performed measurements. This paper describes the development of coordinate systems modelling as a new field of assessing the accuracy of measurements carried out in a quasi-real time. The practical solutions of the so-called virtual machines and virtual measuring systems were described along with the results of their evaluation and validation methodology based on a comparison of obtained results with the results produced by the typical methods of coordinate measurements accuracy assessment.

Author Keywords :

characteristic diagram based correction, structure model based correction, thermo-elastic deformation, online enabled TCP correction coordinate measuring systems, modelling, uncertainty, accuracy

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

IDENTIFICATION OF DYNAMIC CUTTING FORCE COEFFICIENTS BY DIRECT MEASUREMENT OF CUTTING FORCES DURING VIBRATORY CUTTING

K.JEMIELNIAK¹, M. NEJMAN¹, D. SNIEGULSKA-GRADZKA^1
1Department of Automation Machine Tools and Metal Cutting, Faculty of Production Engineering, Warsaw University of Technology, Poland

Abstract

This paper presents the methodology of measuring the instantaneous cutting forces during vibratory cutting. It is based on elastically supported dynamometer vibrating with the tool during chatter. Acceleration of the dynamometer measured simultaneously allows for evaluation and elimination of inertia forces acting on the oscillating dynamometer. Displacements of the dynamometer and the tool in the feed direction during orthogonal cutting are measured by the contactless inductive sensor. The measurements allow for determination of averaged or instantaneous dynamic cutting force coefficients and their dependence on cutting conditions.

Author Keywords :

chatter, cutting force, modelling,

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

ANALYSIS OF MECHANICAL CHARACTERISTICS OF FACE MILLING PROCESS OF Ti6Al4V ALLOY USING EXPERIMENTAL AND SIMULATION DATA

H. Piotr NIESLONY¹, Wit GRZESIK¹, Marian BARTOSZUK¹, Witold HABRAT^2
1Opole University of Technology, Faculty of Mechanical Engineering, Opole, Poland
²Rzeszow University of Technology, Faculty of Mechanical Engineering and Aeronautics, Rzeszow, Poland

Abstract

This paper presents experimental and 3D FEM simulation results obtained for the Johnson-Cook material constitutive model and variable cutting conditions. Face milling tests were carried out using a Ti6Al4V titanium alloy as the workpiece and coated carbide indexable inserts. CAD models of the cutting tool insert and the face milling head were generated and implemented into FEM package used. The machining conditions were selected based on real production data from aerospace sector. In particular, changes of power and specific cutting energy were analyzed in terms of the rotation angle of the milling head and the ratio of the uncut chip thickness against the cutting edge radius.

Author Keywords :

characteristic diagram based correction, structure model based correction, thermo-elastic deformation, online enabled TCP correction FEM simulation, milling process, titanium alloy, cutting forces

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

INVESTIGATION OF SEQUENTIAL MACHINING PROCESSES IN TERMS OF POWER CONSUMPTION AND SURFACE QUALITY

Roman CHUDY¹, Wit GRZESIK^1
1Opole University of Technology, Faculty of Mechanical Engineering, Opole, Poland

Abstract

This paper presents the practical application of a power measurement system based on computer processing of signals generated by current and voltage sensors connected with spindle and axis driving electric motors. By using LabView data acquisition system, the total power and its components were recorded during machining operations. The experimental study concerns the power consumption and surface roughness produced in a sequential machining process consisting of hard turning and ball burnishing operations under variable machining parameters. In particular, some machining routines including finish hard machining and both single and multi-pass ball burnishing of hard surfaces were performed and compared. Finally, the optimization procedure based on these technological criteria was proposed.

Author Keywords :

characteristic diagram based correction, structure model based correction, thermo-elastic deformation, online enabled TCP correction hard turning, ball burnishing, power consumption surface finish

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

MEASURING THE DYNAMIC TWISTING BEHAVIOUR OF SAW BLADES IN THE KERF DURING THE SAWING PROCESS

Daniel ALBRECHT¹, Thomas STEHLE^1
1University of Stuttgart, Institute for Machine Tools, Stuttgart, Germany

Abstract

Vibrations may occur in all kinds of production processes. Particularly the kinematics of band saws with their thin and unstable structure of the saw blade causes high vibrations, which generate, on the one hand, a high acoustic level. On the other hand, the impact can be seen as grooves on the surface of the workpiece. To optimize the sawing process, the vibration behaviour of the saw blades is investigated by experiment on a test band saw with a contactless measuring system during the sawing process of steel. The focus here is on the twisting of the saw blade in the kerf. The sawing parameters of cutting speed and feed rate are varied here in a wide range to examine the stability of the process and the occurring displacement of the saw blade. The results of this investigation indicate that the saw blade in the kerf shows a characteristic behaviour, which is subject to the cutting parameters. It is obvious that the performance of the process depends not only on the cutting process but also on the tensile state of the saw blade affected by the design of the saw frame, the saw blade guides and the saw blade tension. The results obtained are able to support future developments and identify an optimization potential for the sawing process.

Author Keywords :

band saw, cutting,vibration, measurement

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

IMPLEMENTATION AND DEMONSTRATION OF CHARACTERISTIC DIAGRAM AS WELL AS STRUCTURE MODEL BASED CORRECTION OF THERMO-ELASTIC TOOL CENTER POINT DISPLACEMENTS

Matthias PUTZ¹, Steffen IHLENFELDT², Bernd KAUSCHINGER², Christian NAUMANN¹,Xaver THIEM², Mirko RIEDEL^2
1Fraunhofer Institute for Machine Tools and Forming Technology IWU
²Dresden University of Technology TUD

Abstract

In milling machines, waste heat from motors, friction effects on guides and most importantly the milling process itself greatly affect positioning accuracy and thus production quality. Therefore, active cooling and lead time are used to reach thermal stability. A cheaper and more energy-efficient approach is to gather sensor data from the machine tool to predict and correct the resulting tool center point displacement. Two such approaches are the characteristic diagram based and the structure model based correction algorithms which are briefly introduced in this paper. Both principles have never been directly compared on the same demonstration machine, under the equal environmental conditions and with the same measurement setup. The paper accomplishes this comparison ona hexapod kinematics examined in a thermal chamber,where the effectiveness of both approaches is measured and the strengths and weaknesses of both are pointed out.

Author Keywords :

characteristic diagram based correction, structure model based correction, thermo-elastic deformation, online enabled TCP correction

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

SYSTEM DYNAMICS AS A DECISION SUPPORT SYSTEM FOR MACHINE TOOL SELECTION

T.F. ADANE¹, Mihai NICOLESCU^1
1KTH Royal Institute of Technology, Department of Production Engineering, Division of Machine and Process Technology, Stockholm, Sweden

Abstract

The worldwide competitive economy, the increase in sustainable issue and investment of new production line is demanding companies to choose the right machine from the available ones. An improper selection can negatively affect the overall performance of the manufacturing system like productivity, quality, cost and company’s responsive manufacturing capabilities. Thus, selecting the right machine is desirable and substantial for the company to sustain competitive in the market. The ultimate objective of this paper is to formulate a framework for machining strategy and also provide methodology for selecting machine tool from two special purpose machine tools in consideration of interaction of attributes. A decision support system for the selection of machine tool is developed. It evaluates the performance of the machining process and enhances the manufacturer (decision maker) to select the machine with respect to the performance and the pre-chosen criteria. Case study was conducted in a manufacturing company. A system dynamics modelling and simulation techniques is demonstrated towards efficient selection of machine tool that satisfy the future requirement of engine-block production.

Author Keywords :

machine selection; decision making, performance analysis, system dynamics modelling

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

PROCESS FACTORS OF IMPACT ON OEE FOR LATHES FOR MACHINING OF WHEELSET

Roman STRYCZEK¹, Wojciech SZCZEPKA^2
1University of Bielsko-Biała , Faculty of Mechanical Engineering and Computer Science, Bielsko-Biała, Poland
²Siemens sp. z o. o., Industry Automation and Drive Technologies, Katowice, Poland

Abstract

Lathes for machining of wheelsets are the specific class of production means, for which the maintaining of satisfactorily high value of coefficient of overall equipment effectiveness (OEE) is very difficult and depends on many different factors. In this study it has been focused on the process factors which influence shaping of OEE for this group of lathes. These include: optimizing the geometry of the wheel flange, identifying and optimization of partition of machining allowance, segmentation and parameterization of machining programs, adaptive control of roughing as well as detecting and reducing of occurrence of slippage between the drive rollers and the machined wheel. A particularly difficult problem is to detect and avoid slippage of drive rollers at the moment of stopping of the machined wheelset, as a result of occurrence of excessive cutting resistances. In the study it has been presented a new method for detecting of slippage and reacting through synchronous actions, to the occurrence of slippage in the friction drive lathes. The method described in this work has been implemented in real industrial conditions.

Author Keywords :

wheelset machining, optimization, friction drive, adaptive control

CONTENTS

JOURNAL OF MACHINE ENGINEERING

o article: Knowledge Based Engineering as a Condition of Effective Mass Production of Configurable Products by Design Automation (GORSKI F., ZAWADZKI P.,HAMROL A.), pp. 5-30
o article: Multicriteria Optimization of Manufacturing Processes Taking into Account The Validity Criteria (PLONKA S., LOREK L.R.,), pp. 31-48
o article: A Method of Object-Oriented Symbolical Description and Evaluation of Machine Elements Using Antipatterns (KACALAK W.,MAJEWSKI M., TUCHOLKA A.), pp. 49-69
o article: Combination of Criteria for Controller Parameterisation in the Timea and Frequency Domain by Simulation-Based Optimisation (HIPP K., UHRIG M., HELLMICH A., SCHLEGEL H., NEUGEBAUER R.), pp. 70-81
o article: DRive Data Acquisition for Controller Internal Monitoring Functions (HELLMICH A., QUELLMALZ J., SCHOEBERLEIN Ch., SCHLEGEL H., PUTZ M.), pp. 82-94
o article: A Method and New Parameters for Assessing the Active Surface Topography of Diamond Abrasive Films (KACALAK W., TANDECKA K., MATHIA T.G.), pp. 95-108

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© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

KNOWLEDGE BASED ENGINEERING AS A CONDITION OF EFFECTIVE MASS PRODUCTION OF CONFIGURABLE PRODUCTS BY DESIGN AUTOMATION

Filip GORSKI¹, Przemyslaw ZAWADZKI¹, Adam HAMROL^1
1Poznan University of Technology, Chair of Management and Production Engineering, Poznan, Poland

Abstract

The paper presents possibilities of improving design and manufacturing preparation processes of configurable (variant) products in scope of realization of mass customization strategy. Knowledge based engineering tools are presented as a base for building systems for automation of design and manufacturing preparation. Methodologies of building KBE systems are presented and described, authors' own methodology is presented along with selected cases of its use. It is proven that reduction of time needed for design and manufacturing preparation can be vast, use of KBE systems as a way of manufacturing optimization of configurable products.

Author Keywords :

mass customization, design automation, Knowledge Based Engineering

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

MULTICRITERIA OPTIMIZATION OF MANUFACTURING PROCESSES TAKING INTO ACCOUNT THE VALIDITY CRITERIA

Stanislaw PLONKA¹, Late Roman LOREK^1
1University of Bielsko-Biala, Department of Manufacturing Technology and Automation, Bielsko-Biala, Poland

Abstract

In the paper a method is presented of the best variant selection of a manufacturing process of a rotor to open end spinning machine with use of original optimization proceeding based on adopted criteria, taking into consideration their importance. Unit manufacturing cost and five criteria of manufacturing quality were taken as criteria to the assessment. The assessment criteria resulted from calculations and measurements were normalized. Knowledge of experts was used to determine importance of the criteria taken to the assessment. Each from the experts had built his own importance matrix of the assessment criteria, comparable in pairs, using the Saaty's method. The weights of individual criteria were determined on the basis of cumulative matrix. In the next stage of the proceeding, normalized decisions were created by raising each assessment to a power equal to corresponding weight. In the last stage of the proceeding, a single optimal ordering comprising the smallest s-th components of the individual decisions d₁, d₂,..., d_m was created. A variant which corresponds to the largest component of the optimal ordering is assumed as the best variant.

Author Keywords :

University of Bielsko-Biala, Department of Manufacturing Technology and Automation, Bielsko-Biala, Poland

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

A METHOD OF OBJECT-ORIENTED SYMBOLICAL DESCRIPTION AND EVALUATION OF MACHINE ELEMENTS USING ANTIPATTERNS

Wojciech KACALAK¹, Maciej MAJEWSKI¹, Andrzej TUCHOŁKA^1
1Koszalin University of Technology, Faculty of Mechanical Engineering, Koszalin, Poland

Abstract

Authors propose a method of normalizing and analyzing structures, enabling automated cross-comparison of features observed in tested structures against predefined ones (both correct and incorrect reference elements). Application of this method, enables usage of numerical methods and neural networks for rapid classification of elements, while maintaining high level of flexibility, uncertainty and variety of input data. Additionally, a language, enabling symbolic representation of mechanical elements is presented and used in the demonstration of the proposed method applied to mechanical shafts. Authors explore one simple, and two more complex calculation models aimed at automation of the evaluation and rating of mechanical elements, with a purpose of improving the design and quality monitoring processes. Increase in efficiency of these processes results from applying proposed method as a tool for reducing common mistakes faults, quality assessment time of large amounts of similar elements, or automatic suggesting of possible solutions.

Author Keywords :

machine design, automated design systems,structural feature language, antipatterns

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

COMBINATION OF CRITERIA FOR CONTROLLER PARAMETERISATION IN THE TIME AND FREQUENCY DOMAIN BY SIMULATION-BASED OPTIMISATION

Kevin HIPP¹, Max UHRIG¹, Arvid HELLMICH¹, Holger SCHLEGEL¹, Reimund NEUGEBAUER^1
1Technische Universitaet Chemnitz, Faculty of Mechanical Engineering, Professorship for Machine Tools and Forming Technology, Chemnitz, Germany

Abstract

The position controller cascade is widely used in standard industrial controllers. Its controller parameterisation is commonly performed by either applying basic tuning rules or by carrying out not comprehensible design automatisms.In this paper an alternative approach to parameterise the cascade in one step is presented. It bases on established methods within the field of optimisation research - specifically the so-called "simulation-based optimisation" (SBO), which can also handle non-linear models and various constrains. Own research showed, that criteria in the time domain as well as in the frequency domain are suitable optimisation criteria. However, both types have individual advantages and disadvantages. Therefore, in this research, selected representatives from both types were combined as new multi-objective optimisation criteria and investigated according to their performance. Investigations were performed for a test rig model (third order transfer function plus dead time and friction).The paper presents fundamentals of the SBO and a description of the optimisation criteria, obtained results as well as their verification on the test rig. Also, the derived controller parameterisations are compared to the integrated tuning automatism.

Author Keywords :

simulation-based optimisation, optimisation criteria,controller parameterisation,time and frequency domain

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

DRIVE DATA ACQUISITION FOR CONTROLLER INTERNAL MONITORING FUNCTIONS

Arvid HELLMICH¹, Johannes QUELLMALZ¹,Chris SCHÖBERLEIN¹, Holger SCHLEGEL¹,Matthias PUTZ^1
1Technische Universitaet Chemnitz, Faculty of Mechanical Engineering, Professorship for Machine Tools and Forming Technology, Chemnitz, Germany

Abstract

With the current trend of increasing automation, leading to self-organizing machine tools and production machines ("Industry 4.0"), data acquisition and processing becomes more and more important. Based on these data, new monitoring functions and identification methods can be implemented in the machine control. Depending on the algorithms, also drive internal data, such as the actual torque, or the power consumption of the machine axes are required, partially at high sample rates. State of the art computerized numerical controllers (e.g. SIEMENS 840D sl) however, are characterized by a separation of drive system and controller. Drive data, which is not included in the standard bus-connection are difficult to access by the superordinated CNC. The paper addresses this problem, presents and compares various concepts of drive data transfer to a standard industrial CNC/PLC. Subsequently, the most convenient method, which utilizes a drive-internal data recorder is chosen for implementation. It offers flexible drive data acquisition through the PLC at high sample rates, carried out block wise. Experimental results are shown to prove the functionality. Finally, ideas for continuative monitoring and identification methods are discussed

Author Keywords :

computerized numerical controller, drive data, identification, monitoring

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2016 Poland

A METHOD AND NEW PARAMETERS FOR ASSESSING THE ACTIVE SURFACE TOPOGRAPHY OF DIAMOND ABRASIVE FILMS

Wojciech KACALAK¹, Katarzyna TANDECKA¹,Thomas G.MATHIA^2
1Koszalin University of Technology, Faculty of Mechanical Engineering, Koszalin, Poland
²Laboratoire de Tribologie et Dynamique des Systemes (LTDS) - C.N.R.S., École Centrale de Lyon, France

Abstract

This paper describes the methodology and results of research on the tribological characteristics of the surfaces of diamond abrasive films using a stereometric analysis. Abrasive films are used in various finishing processes of surfaces with very high smoothness and accuracy. A morphological analysis of surface vertexes in the plane that is parallel to the film surface and the perpendicular direction allowed an assessment of the distances between particles by means of a decomposition of the surface into Voronoi cells. When studying the formation of the aggregates of diamond particles and the spaces between them, one may infer about the machining potential of the abrasive film and determine the recommended kinematic conditions of the film that ensures e maximum use of this potential.Owing to the investigations related to the morphology of diamond abrasive films,one can observe relevant characteristic abrasive aggregates that vary in term of size and shape depending on particle sizes.Units with elongated shapes have a superior machining ability in relation to spherical-shaped units. One of significant parameters proposed that describe the technological potential of abrasive films is the edge length to width ratio of diamond units. Different operating modes are discussed. A statistical analysis of the dynamics observed of abrasive interfaces allowed a pertinent description of the abrasive process taking into consideration nominal and apparent as well as abrasively efficient morphologies.

Author Keywords :

mikcrofinishing films, diamond, active surface