CONTENTS

SPONSORING
Issue No.1, 2018 is sponsored by the Ministry of Science
and Higher Education of Poland - funding for DOI

JOURNAL OF MACHINE ENGINEERING

o article: Intelligent Machining: Real-Time Tool Condition Monitoring and Intelligent Adaptive Control Systems (HASSAN M., SADEK A., ATTIA M. H., THOMSON V.), pp. 5-17
o article: Development of Environmentally-Friendly Technologies Based on the Double-Eco Model ? An Evaluation Platform (PENA-GONZALEZ L. E., Da SILVA P., TANABE I.), pp. 18-31
o article: The Analysis of Environmental and Human Impacts of Using Strong Alkaline Water for Cooling During Machining (Da SILVA P., TANABE I., JUNIOR D.C.R., TAKAHASHI S.), pp. 32-44
o article: Development and Manufacturing of Arduino Based Electrochemical Discharge Machine (PAWAR P., KUMAR A., BALLAV R.), pp. 45-60
o article: Numerical Flow Simulation of Rotating Circular Saw Blades for the Investigation of Sound Generation Mechanisms (MÖHRING H. Christian., STEHLE T., GÜZEL K., ZIZELMANN Ch.), pp.61-71
o article: The Effect of Changes in Depth of Cut on Surface Roughness in Machining of AISI 316 Stainless Steel (JAROSZ K., LÖSCHNER P.), pp. 72-79
o article: The Effect of Alternative Cutter Paths on Flatness Deviations in the Face Milling of Aluminum Plate Parts (DOBRZYNSKI M., CHUCHALA D., ORLOWSKI K A.), pp. 80-87
o article: Compensation of Systematic Errors of Damaged Probe for on-Machine Measurement (WOZNIAK A., JANKOWSKI M.), pp. 88-94
o article: Decomposition Algorithm for Tool Path Planning for Wire-Arc Additive Manufacturing (NGUYEN L., BUHL J., BAMBACH M.), pp. 95-106
o article: A Review and Analysis of the Historical Development of Machine Tools into Complex Intelligent Mechatronic Systems of Sculptured Surfaces Using the Toroidal Cutter (GUERGOV S.), pp. 107-119

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© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

INTELLIGENT MACHINING: REAL-TIME TOOL CONDITION MONITORING AND INTELLIGENT ADAPTIVE CONTROL SYSTEMS

Mahmoud HASSAN¹, Ahmad SADEK²,M. Helmi ATTIA^1,2,Vincent THOMSON^1
1Department of Mechanical Engineering, McGill University, Montreal, QC, Canada
^1,2Aerospace Structures, Materials and Manufacturing, National Research Council Canada, Montreal, QC, Canada

Abstract

Unmanned manufacturing systems has recently gained great interest due to the ever increasing requirements of optimized machining for the realization of the fourth industrial revolution in manufacturing 'Industry 4.0'. Real-time tool condition monitoring (TCM) and adaptive control (AC) machining system are essential technologies to achieve the required industrial competitive advantage, in terms of reducing cost, increasing productivity, improving quality, and preventing damage to the machined part. New AC systems aim at controlling the process parameters, based on estimating the effects of the sensed real-time machining load on the tool and part integrity. Such an aspect cannot be directly monitored during the machining operation in an industrial environment, which necessitates developing new intelligent model-based process controllers. The new generations of TCM systems target accurate detection of systematic tool wear growth, as well as the prediction of sudden tool failure before damage to the part takes place. This requires applying advanced signal processing techniques to multi-sensor feedback signals, in addition to using ultra-high speed controllers to facilitate robust online decision making within the very short time span (in the order of 10 ms) for high speed machining processes. The development of new generations of Intelligent AC and TCM systems involves developing robust and swift communication of such systems with the CNC machine controller. However, further research is needed to develop the industrial internet of things (IIOT) readiness of such systems, which provides a tremendous potential for increased process reliability, efficiency and sustainability.

Author Keywords :

adaptive control,tool condition monitoring,intelligent machining

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

DEVELOPMENT OF ENVIRONMENTALLY-FRIENDLY TECHNOLOGIES BASED ON THE DOUBLE-ECO MODEL - AN EVALUATION PLATFORM

Luis Edoardo PENA-GONZALEZ¹, Paulo Da SILVA¹, Ikuo TANABE^2
1Nagaoka University of Technology, Graduate School of Mechanical Engineering, Niigata, Japan
²Nagaoka University of Technology, Department of Mechanical Engineering, Niigata, Japan

Abstract

In recent years, the urgency to create environmentally-friendly technologies has dramatically increased. However, these technologies are usually not adopted due to their large cost and low profit. Previouslythe "Double-ECO model" has been proposed as a methodology that reconciles both "Economy" and "Ecology", which relies on the exploration of technology alternatives that offer an improved mechanical performance. Here, as mechanical performance, cost and environmental impact were meant to be approached under the same degree of priority, this model was thought to offer the basis for a broader technology development framework. The current research initiates said framework by proposing an evaluation platform, which through a transition from a focus on environmental-friendliness towards an improved eco-efficiency definition lays groundwork for an automated evaluation. This was done by defining a dimensionless evaluation parameter based on existing methodologies and referred as the "DE Index". This paper applied the proposed evaluation method into a machine tool lubrication technology example. It was concluded that, (1) the platform was able to effectively compare technologies under the proposed Eco-efficiency parameter, (2) the developed technology possesse improvements in the environmental pollution output, mechanical performance and cost when compared to conventional technologies.

Author Keywords :

Eco-efficiency, lubrication, life cycle assessment, Mahalanobis-Taguchi system

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

THE ANALYSIS OF ENVIRONMENTAL AND HUMAN IMPACTS OF USING STRONG ALKALINE WATER FOR COOLING DURING MACHINING

Paulo Da SILVA¹, Ikuo TANABE¹, Da Cruz R. JUNIOR², Satoshi TAKAHASHI^3
1Nagaoka University of Technology, Department of Mechanical Engineering, Japan
²Universidade Nacional Timor Lorosae, Department of Mechanical Engineering, Timor Leste
³Nagaoka University of Technology, Centre for Integrated Technology Support, Japan

Abstract

An Eco-friendly manufacturing approach is important for the environment. Enhancing machining performances is not only required to improve product's quality, time saving, and reduces costs; it is also contributed to the environmental protection efforts. Cooling is important aspect for obtaining this purpose. Therefore the benefits of Strong Alkaline Water (SAW) cooling method was assessed and compared with conventional wet cutting method. An experiment was performed at Nagaoka University of Technology machining centre. Three machine tools including a milling machine, a drilling machine and a turning machine were used. The study shows that using SAW for cooling is far more efficient than conventional cooling method. It reduces annual global warming potential by 72.95%, acidification potential 98.18%, ozone depletion potential 99.6%, smog formation potential 85.71% and human toxicity potential 42.86% compare with conventional method. The study concludes that besides inhibiting corrosion, prolonging tool life, improving surface roughness of final cutting and reducing energy usage, strong alkaline water cooling is an environmentally friendly approach and has positive impact on human health.

Author Keywords :

eco-friendly, strong alkaline water, emission and cooling

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

DEVELOPMENT AND MANUFACTURING OF ARDUINO BASED ELECTROCHEMICAL DISCHARGE MACHINE

Pravin PAWAR¹, Amaresh KUMAR¹, Raj BALLAV^1
1Department of Manufacturing Engineering, National Institute of Technology, Jamshedpur, Jharkhand, India, 831014

Abstract

The machining of non-conducting materials is very difficult due to its brittleness and hardness properties. The electrochemical discharge machining (ECDM) process is the hybrid non-traditional manufacturing technology because it is combined with two processes namely electro-chemical machining (ECM) and electro-discharge machining (EDM) which can cut non-conducting and conducting materials. Hence from this view, the present work is undertake understand the development and manufacturing of ECDM setup based on Arduino. The 2D drawings are drawn by using AutoCAD software and 3D model is developed with CATIA software. The ECDM machine setup is manufactured accurately according to the 2D drawings and 3D model. The gravity feed mechanism is applied to workpiece materials and the speed of cathode tool electrode is controlled by using Arduino programming through the computer. The preliminary experimental trials were carried out and micro-hole drills on the glass and ceramic materials are successfully achieved. The present article provides fundamental and detailed building study of ECDM setup which includes information from the starting sketch up to the real prototype model. This work may be useful to make advanced machining setup as well as may solve the basic difficulties of new researchers in this field.

Author Keywords :

ECDM, 2D drawing, 3D model, non-conducting materials, Arduino Uno

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

NUMERICAL FLOW SIMULATION OF ROTATING CIRCULAR SAW BLADES FOR THE INVESTIGATION OF SOUND GENERATION MECHANISMS

H.-Christian MÖHRING¹, Thomas STEHLE¹, Kamil GÜZEL¹, Christoph ZIZELMANN^1
1University of Stuttgart, Institute for Machine Tools (IfW), Stuttgart, Germany

Abstract

Emission of airborne sound in the production industry is endangering the employees' health and is lowering productivity. Circular saw blades in particular cause high sound pressure levels. Therefore, the tool geometry of saw blades should be improved in the sense that the emission of airborne sound is lowered. In this work, the basics for the tool optimization regarding the emission of airborne sound are elaborated. To avoid high costs for various prototypes and experimental investigations, a computational fluid dynamics (CFD) simulation is used. By this, the effects of the adjustments of the geometry on the fluid mechanics can be researched efficiently. Using the acoustic analogy of Ffowcs-Williams/Hawkings, the results of the numerical flow simulation are converted into the sound pressure level. To validate the calculated results, previously conducted experiments are used for comparison. The calculated results correspond well to the values from the experimental measurements. Hence, it is possible to use the developed method to predict the influence of geometry adjustments on the acoustic behaviour, making the optimization process possible. In an outlook, the concept for an optimization loop is explained, which couples the CFD simulation with a parameterized geometry model and an evaluation algorithm.

Author Keywords :

flow simulation, emission of airborne sound, acoustic examination

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

THE EFFECT OF CHANGES IN DEPTH OF CUT ON SURFACE ROUGHNESS IN MACHINING OF AISI 316 STAINLESS STEEL

Krzysztof JAROSZ¹, Piotr LÖSCHNER^1
1Opole University of Technology, Faculty of Mechanical Engineering, Department of Manufacturing Engineering and Automation, Opole, Poland

Abstract

Currently, process optimization is an important part of design of CNC toolpath, allowing overall process improvement in accordance to a range of criteria. Available CAE software for CNC toolpath optimization works only by changing the feed rate value specified in the base toolpath. The authors are planning to devise a solution allowing for optimization of other process parameters, including depth of cut. In some cases, it would be important for surface roughness to remain unaltered after optimization by means of increasing depth of cut. In this work, the effect of depth of cut on surface roughness was investigated. Depth of cut was altered for the roughing pass, while technological parameters for the finish pass remained constant. Roughness measurements were performed on-machine after rough turning and finish turning. The authors have found that depth of cut has a noticeable effect on investigated roughness parameters, both in the case of rough turning and subsequent finish turning operations

Author Keywords :

AISI 316L stainless steel, surface roughness, depth of cut

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

THE EFFECT OF ALTERNATIVE CUTTER PATHS ON FLATNESS DEVIATIONS IN THE FACE MILLING OF ALUMINUM PLATE PARTS

Michal DOBRZYNSKI¹, Daniel CHUCHALA¹, Kazimierz A. ORLOWSKI^1
1Gdansk University of Technology, Mechanical Engineering Faculty, Department of Manufacturing Engineering and Automation, Gdansk, Poland

Abstract

In this paper the relationships between the alternative machining paths and flatness deviations of the aluminum plate part, were presented. The flatness tolerance of the main surface of the plate part has crucial meaning due to the assembly requirement of piezoelectric elements on the radiator. The aluminum bodies under investigation are the base part of the radiators with crimped feathers for the train industry. The surface of the aluminum plate part was milled using three different milling strategies: along of longer or shorter side of workpiece and at an angle of 45°. The aluminum bodies were machined on milling centre ecoMILL 70 DMG MORI. The flatness deviation measurements were carried out on the Coordinated Measuring Machine Altera 7.5.5 Nikon Metrology NV. These measurements were made during the manufacturing process of the radiator, namely after machining, however, before the process crimping of feathers. The results that were obtained enables the validation of assumed milling path strategies in connection of the subsequent machining and assembly processes.

Author Keywords :

process precision, face milling, radiator, paths strategies, flatness deviation

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

COMPENSATION OF SYSTEMATIC ERRORS OF DAMAGED PROBE FOR ON-MACHINE MEASUREMENT

Adam WOZNIAK¹
Michal JANKOWSKI^1
1Warsaw University of Technology, Faculty of Mechatronics, Institute of Metrology and Biomedical Engineering, Warsaw, Poland

Abstract

Spatial characteristic of triggering radius of the damaged probe for the CNC machine tools has been presented. In such case a clear distortion of the probe performance characteristic and a significant increase in probe errors have been observed. Then, to such a damaged probe, a variable speed correction method of systematic errors was used.By setting proper measurement speeds, varying for different measurement directions, errors of the probe can be significantly reduced.

Author Keywords :

on-machine measurement, touch-trigger probe, errors compensation

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

DECOMPOSITION ALGORITHM FOR TOOL PATH PLANNING FOR WIRE-ARC ADDITIVE MANUFACTURING

Lam NGUYEN¹, Johannes BUHL¹, Markus BAMBACH^1
1Brandenburg University of Technology Cottbus-Senftenberg, Dept. of Mechanical Design and Manufacturing, Cottbus, Germany

Abstract

Three-axis machines are limited in the production of geometrical features in powder-bed additive manufacturing processes. In case of overhangs, support material has to be added due to the nature of the process, which causes some disadvantages. Robot-based wire-arc additive manufacturing (WAAM) is able to fabricate overhangs without adding support material. Hence, build time, waste of material, and post-processing might be reduced considerably. In order to make full use of multi-axis advantages, slicing strategies are needed. To this end, the CAD (computer-aided design) model of the part to be built is first partitioned into sub-parts, and for each sub-part, an individual build direction is identified. Path planning for these sub-parts by slicing then enables to produce the parts. This study presents a heuristic method to deal with the decomposition of CAD models and build direction identification for sub-entities. The geometric data of two adjacent slices are analyzed to construct centroidal axes. These centroidal axes are used to navigate the slicing and building processes. A case study and experiments are presented to exemplify the algorithm.

Author Keywords :

additive manufacturing, part decomposition, multi-direction slicing, WAAM

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

A REVIEW AND ANALYSIS OF THE HISTORICAL DEVELOPMENT OF MACHINE TOOLS INTO COMPLEX INTELLIGENT MECHATRONIC SYSTEMS

Sasho GUERGOV^1
1Technical University - Sofia, Bulgaria

Abstract

This paper presents an analytical review of the development of machine tools (MT) into complex mechatronic systems. The basic periods, inventions and achievements in their historical development are marked which are represented in seven stages depending on the most essential changes for each period. Other fundamental and important discoveries and inventions are given along with the immediate achievements and changes which have affected the development of MT. A diagram of the changes in the relationship between the MT mechanical, electronic and software components is presented depending on the rate of development of the different stages as well as an opinion is shared on the conceptual schema of the environment of a future intelligent MT.

Author Keywords :

intelligence, machine tool, mechatronic system, historical perspective

CONTENTS

SPONSORING
Issue No.2, 2018 is sponsored by the Ministry of Science
and Higher Education of Poland - funding for DOI

JOURNAL OF MACHINE ENGINEERING

o article: Machine Tool Ability Representation: A Review (SADASIVAM L., ARCHENTI A., SANDBERG U.), pp. 5-16
o article: Machine Tool Distortion Estimation Due to Environmental Thermal Fluctuations - A Focus on Heat Transfer Coefficient (Da SILVA P., PENA-GONZALEZ L.E., TANABE I.), pp. 17-30
o article: Machine Learning in SMED (KUTSCHENREITER-PRASZKIEWICZ I.), pp. 31-40
o article: Efficient Quantification of Free and Forced Convection via the Decoupling of Thermo-Mechanical and Thermo-Fluidic Simulations of Machine Tools (GLAENZEL J., IHLENFELDT S., NAUMANN Ch., PUTZ M.), pp. 41-53
o article: Determination of Influence of the Parameters Connected with the Stabilization of the Position on the 5-Axis Manipulators' Operation Accuracy (GASKA A., HARMATYS W., GRUZA M., GASKA P., SLADEK J.), pp.54-63
o article: Enhancing Laser Step Diagonal Measurement by Multiple Sensors for Fast Machine Tool Calibration (DAHLEM P., MONTAVON B., PETEREK M., SCHMITT R.H. ), pp. 64-73
o article: Complementing and Enhancing Definitions of Line Profile Composite Tolerance Imposed by ISO Geometrical Product Specification (YAN Y., BOHN M.), pp. 74-84
o article: Detection of Wear Parameters Using Existing Sensors in the Machines Environment to Reach Higher Machine Precession (SCHMITT R R., DECRESSIN R., DIETRICH F., DRÖDER K.), pp. 85-96
o article: Assessment of Surface Roughness in MQl Assisted Turning Process of Titanium Alloy with Application of Topsis-AHP Method (BARTOSZUK M., GUPTA M K.), pp. 97-105
o article: Investigation of a High-Forced Cooling System for the Elements of Heat Power Installations (GENBACH A.A., BONDARTSEV D.Y., ILIEV I.K.), pp. 106-117

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© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

MACHINE TOOL ABILITY REPRESENTATION: A REVIEW

Logesh SADASIVAM^1,2, Andreas ARCHENTI^1,2, Ulf SANDBERG^1
1Manufacturing and Metrology Systems Division, Department of Production Engineering, KTH Royal Institute of Technology, Stockholm, Sweden
^1,2 Department of Sustainable Production Development, KTH Royal Institute of Technology, Södertälje, Sweden

Abstract

Smart manufacturing and predictive maintenance are current trends in the manufacturing industry. However, the holistic understanding of the machine tool health condition in terms of accuracy, functions, process and availability is still unclear. This uncertainty renders the development of models and the data acquisition related to machine tool health condition ineffective. This paper proposes the term machine tool ability as an interconnection between the accuracy, functions, the process and the availability to overcome the lack of the holistic understanding of the machine tool. This will facilitate the further development of qualitative or quantitative methods as well as models. The research highlights the challenges and gaps to understand the machine tool ability.

Author Keywords :

machine tool, ability, health, predictive maintenance, accuracy

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

MACHINE TOOL DISTORTION ESTIMATION DUE TO ENVIRONMENTAL THERMAL FLUCTUATIONS - A FOCUS ON HEAT TRANSFER COEFFICIENT

Paulo Da SILVA¹, Luis Edoardo PENA-GONZALEZ¹, Ikuo TANABE², Satoshi TAKAHASHI^3
1Nagaoka University of Technology, Graduate School of Mechanical Engineering, Niigata, Japan
²Nagaoka University of Technology, Department of Mechanical Engineering, Niigata, Japan
³Nagaoka University of Technology, Center for Integrated Technology Support, Niigata, Japan

Abstract

Thermally induced errors have been approached in multiple ways due to the influence these have over the positional accuracy of a machine tool. Here, approaches regarding environmental thermal fluctuations surrounding a machine tool remain to be explored in detail. These fluctuations have been explored in terms of the heat transfer coefficient and thermal radiation of the machine shop walls, as well as in terms of seasonality and varying thermal gradients. This paper presents additional considerations regarding environmental temperature perturbations, as heat transfer coefficient fluctuation in the machine shop were thought to play a significant role in machine tool thermal deformation a broader term for these phenomena, environmental thermal fluctuations, was defined and evaluated. Specifically, an environmental thermal data survey of a machine shop was explored. This data was then applied to a NC milling machine and a CNC jig borer FEM analyses and compared to experimental data. FEM simulations were then used to demonstrate that convection regimes and heat transfer coefficient values at a machine shop have a significant influence over machining precision. Here, under maximum and minimum heat transfer coefficient values, the NC milling machine and CNC jig borer simulations results showed an error of cut difference up to 36.5 ?m and 18.17 ?m, respectively. In addition, as the importance of the heat transfer coefficient was highlighted, considerations regarding machine tool surface color were deemed relevant and were described.

Author Keywords :

environmental thermal fluctuations, thermal deformation, machine tool, heat transfer coefficient

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

MACHINE LEARNING IN SMED

Izabela KUTSCHENREITER-PRASZKIEWICZ^1
1University of Bielsko-Biala, Bielsko-Biala, Poland

Abstract

The paper discusses Single Minute Exchange of Die (SMED) and machine learning methods, such as neural networks and a decision tree. SMED is one of lean production methods for reducing waste in the manufacturing process, which helps to reorganize a conversion of the manufacturing process from current to the next product. SMED needs set-up activity analyses, which include activity classification, working time measurement and work improvement. The analyses presented in the article are focused on selecting the time measuremen method useful from the SMED perspective. Time measurement methods and their comparison are presented in the paper. Machine learning methods are used to suggest the method of time measurement which should be applied in a particular case of workstation reorganization. A training set is developed and an example of classification is presented. Time and motion study is one of important methods of estimating machine changeover time. In the field of time study, researchers present the obtained results by using (linear) multi-linear regression models (MLR), and (non-linear) multi-layer perceptrons (MLP). The presented approach is particularly important for the enterprises which offer make-to-order products. Development of the SMED method can influence manufacturing cost reduction of customized products. In variety oriented manufacturing, SMED supports flexibility and adaptability of the manufacturing system.

Author Keywords :

time standard, human activity, SMED, artificial neural network

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

EFFICIENT QUANTIFICATION OF FREE AND FORCED CONVECTION VIA THE DECOUPLING OF THERMO-MECHANICAL AND THERMO-FLUIDIC SIMULATIONS OF MACHINE TOOLS

Janine GLAENZEL¹, Steffen IHLENFELDT², Christian NAUMANN¹, Matthias PUTZ^1
1Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz, Germany
²Dresden University of Technology, Institute of Machine Tools and Control Engineering, Dresden, Germany

Abstract

Thermo-elastic deformations represent one of the main reasons for positioning errors in machine tools. Investigations of the thermo-mechanical behaviour of machine tools, especially during the design phase, rely mainly on thermo-elastic simulations. These require the knowledge of heat sources and sinks and assumptions on the heat dissipation via convection, conduction and radiation. Forced convection such as that caused by moving assemblies has both a large influence on the heat dissipation to the surrounding air. The most accurate way of taking convection into account is via computational fluid dynamics (CFD) simulations. These simulations compute heat transfer coefficients for every finite element on the machine tool surface, which can then be used as boundary conditions for accurate thermo-mechanical simulations. Transient thermo-mechanical simulations with moving assemblies thus require a CFD simulation during each time step, which is very time-consuming. This paper presents an alternative by using characteristic diagrams to interpolate the CFD simulations. The new method uses precomputed thermal coefficients of a small number of load cases as support points to estimate the convection of all relevant load cases (i.e. ambient conditions).It will be explained and demonstrated on a machine tool column.

Author Keywords :

thermal effects, simulation, machine tool, environment, positioning errors

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

DETERMINATION OF INFLUENCE OF THE PARAMETERS CONNECTED WITH THE STABILIZATION OF THE POSITION ON THE 5-AXIS MANIPULATORS' OPERATION ACCURACY

Adam GASKA¹, Wiktor HARMATYS¹, Maciej Gruza¹, Piotr GASKA¹, Jerzy SLADEK^1
1Cracow University of Technology, Faculty of Mechanical Engineering, Laboratory of Coordinate Metrology, Cracow, Poland

Abstract

The 5-axis systems, especially those that use in their kinematic chain both prismatic joints and revolute kinematic pairs are gaining popularity in many scientific disciplines with manufacturing, metrology and robotics at the forefront. This is therefore important to undertake research aiming in identification of sources of inaccuracies in their functioning and investigation on possibility of eliminating or compensating them. A significant impact on 5-axis kinematic structures accuracy may be assigned to parameters associated with the stabilization of the machine position and angular position, such as position stabilization time, position overshoot and drift of positioning accuracy. These parameters are well described in ISO 9283 standard related to performance criteria and test methods for industrial robots. The methodology presented in this standard is adapted for testing the impact of mentioned parameters for functioning of 5-axis kinematic structures other than industrial robots, which mainly include five-axis coordinate measuring systems and machine tools. A series of experiments performed on five-axis coordinate measuring system is presented in this paper, their results are assessed in a quantitative manner and basing on them a general algorithm for assessing the significance of impact of position stabilization parameters on functioning of the manipulator is proposed.

Author Keywords :

pose accuracy, 5-axis system, LaserTracer, CMM

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

ENHANCING LASER STEP DIAGONAL MEASUREMENT BY MULTIPLE SENSORS FOR FAST MACHINE TOOL CALIBRATION

Philipp DAHLEM¹, Benjamin MONTAVON¹, Martin PETEREK¹, Robert H. SCHMITT^1
1Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Chair of Production Metrology and Quality Management, Aachen, Germany

Abstract

The volumetric performance of machine tools is limited by the remaining relative deviation between desired and real tool tip position. Being able to predict this deviation at any given functional point enables methods for compensation or counteraction and hence reduce errors in manufacturing and uncertainties for on-machine measurement tasks. Time-efficient identification and quanitification of different contributions to the resulting deviation play a key role in this strategy. The authors pursue the development of an optical sensor system for step diagonal measurement methods, which can be integrated into the working volume of the machine due to its compact size, enabling fast measurements of the axes' motion error including roll, pitch and yaw and squareness errors without significantly interrupting the manufacturing process. The use of a frequency-modulating interferometer and photosensitive arrays in combination with a Gaussian laser beam allow for measurements at comparable accuracy, lower cost and smaller dimensions compared to state-of-the-art optical measuring appliances for offline machine tool calibration. For validation of the method a virtual machine setup and raytracing simulation is used which enables the investigation of systematic errors like sensor hardware misalignment.

Author Keywords :

machine tool calibration, step diagonal measurement, integrated calibration system

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

COMPLEMENTING AND ENHANCING DEFINITIONS OF LINE PROFILE COMPOSITE TOLERANCE IMPOSED BY ISO GEOMETRICAL PRODUCT SPECIFICATION

Yiqing YAN¹, Martin BOHN^1
1Research & Development, Dimensional Management, Mercedes-Benz Cars, Daimler AG, Germany

Abstract

According to the ISO Geometrical Product Specifications (GPS), if two or more specifications of the same characteristic are to be indicated, they may be combined as a composite tolerance. Therefore there are no definition differences between the single separate tolerance indicators and their composite tolerance, which is different from the ASME standards. Hereby, the definitions of the combined tolerance which specifies the additional location, orientation and form of tolerance zone are not explicitly defined in the current ISO. It restricts the required definitions of tolerance specifications of a component which are often utilized in practice. However, the required definitions cannot be notated in the technical drawings by using the ISO semantics, because the ISO definitions are insufficient. It causes definition gaps and misinterpretations. This paper focuses on developing the definitions of line profile composite tolerance and suggests a new approach for explicitly defined and function-oriented systematology of line profile composite tolerance. This research is based on the analysis of physical behaviour of geometric feature of a component on a theoretical level. Completed and enhanced definitions in an improved systematology for line profile composite tolerance is formulated which fills the definition gaps and eliminates the deficits in ISO GPS.

Author Keywords :

line profile tolerance, composite tolerance, geometrical product specifications, tolerancing and dimensioning

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

DETECTION OF WEAR PARAMETERS USING EXISTING SENSORS IN THE MACHINES ENVIRONMENT TO REACH HIGHER MACHINE PRECISION

Ricarda Regina SCHMITT¹
Robert DECRESSIN¹, Franz DIETRICH¹, Klaus DRÖDER^1
1TU Branschweig, Institute of Machine Tools and Production Technology, Branschweig, Germany

Abstract

This paper presents methods to plan predictive maintenance for precision assembly tasks. One of the key aspects of this approach is handling the abnormalities during the development phase, i.e. before and during process implementation. The goal is to identify abnormalities which are prone to failure and finding methods to monitor them. To achieve this, an example assembly system is presented. A Failure Mode and Effects Analysis is then applied to this assembly system to show which key elements influence the overall product quality. Methods to monitor these elements are presented. A unique aspect of this approach is exploring additional routines which can be incorporated in the process to identify machine specific problems. As explained within the paper, the Failure Mode and Effects Analysis shows that the resulting quality in a case study from a precision assembly task is dependent on the precision of the rotational axis. Although the rotational axis plays a significant role in the resulting error, it is hard to explicitly find a correlation between its degradation and produced parts. To overcome this, an additional routine is added to the production process, which directly collects information about the rotational axis. In addition to the overallconcept, this routine is discussed and its ability to monitor the rotational axis is confirmed in the paper.

Author Keywords :

predictive maintenance, analysis, precision, predictive model

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

ASSESSMENT OF SURFACE ROUGHNESS IN MQL ASSISTED TURNING PROCESS OF TITANIUM ALLOY WITH APPLICATION OF TOPSIS-AHP METHOD

Marian BARTOSZUK¹, Munish Kumar GUPTA^2
1Faculty of Mechanical Engineering, Opole University of Technology, Opole, Poland
²MED, NIT, Hamirpur (H.P.),INDIA

Abstract

The optimization of surface roughness values considered as one of the most significant issues regarding turning process of titanium alloys with the use of minim quantity lubrication (MQL) method. With such an aim in mind, the application of TOPSIS-AHP method is implemented in order to establish the most favourable cutting parameters for the following values of surface roughness: Ra, Rq and Rz in machining of titanium alloys regarding MQL conditions. The proposed methodology consists of the two stages. At the beginning, tests on turning process were performed on CNC lathe, taking feed rate, approach angle, and cutting speed as input parameters. Then, the TOPSIS-AHP method was applied on the given experimental data and the optimum machining parameters were determined. The findings from current investigations showed that, lower values of cutting speed, feed rate and middle value of approach angle shows the optimal results.

Author Keywords :

titanium alloy, turning parameters, optimization, surface roughness, minimum quantity lubrication

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

INVESTIGATION OF A HIGH-FORCED COOLING SYSTEM FOR THE ELEMENTS OF HEAT POWER INSTALLATIONS

Alexander A. GENBACH¹, David Yu. BONDARTSEV¹, Iliya K. ILIEV^2
1Almaty University of Power Engineering and Telecommunications, Department of Heat Engineering Installations, Almaty, Kazakhstan
²University of Ruse, Department of Thermotechnics, Hydraulics and Ecology, Ruse, Bulgaria

Abstract

The studies of the ultimate thermal flows have been carried out in metallic and poorly heat-conducting porous structures, which operate when gravitational and capillary forces act jointly and cool various devices of thermal power plants in order to create a scientific methodology. The mechanism of destruction of metal vaporizing surfaces and poorly heat-conducting coatings of low porosity made of natural mineral media (granite) has been described on the basis of the problem of thermoelasticity and experimental data. Thermal flow dependences on time of their action and depth of penetration of temperature perturbations were identified based on analogy. Capillary-porous systems have high intensity, heat transport ability, reliability, compactness. The results of calculations and experiment showed that the maximum thickness of the particles that detach under the influence of compression forces for granite coatings is (0.25÷0.3).10-2 m. Sections of compression curves that determine the detachment of particles with dimensions of more than 0.3.10-2 m for large thermal flows and short feed times, are screened by the melting curve, and in the case of small thermal flows and time intervals - the expansion curve.

Author Keywords :

heat transfer control, capillary-porous coatings, natural mineral media, heat-transfer crisis, capillary-porous system, thermal power plants

CONTENTS

SPONSORING
Issue No.3, 2018 is sponsored by the Ministry of Science
and Higher Education of Poland - funding for DOI

JOURNAL OF MACHINE ENGINEERING

o article: Simulation for Instable Floating of Hydrodynamic Guides During Acceleration and at Constant Velocity (ZHANG Y., WITTSTOCK V, PUTZ M.), pp. 5-15
o article: In-Process Control with a Sensory Tool Holder to Avoid Chatter (BLEICHER F., SCHÖRGHOFER P., HABERSOHN Ch.), pp. 16-27
o article: Development of an Automated Assembly Process Supported with an Artificial Neural Network (BOBKA P., HEYN J., HENNINGSON J.O., RÖMER M., ENGBERS T., DIETRICH F., DRÖDER K.), pp. 28-41
o article: Manufacturing and Quality Assurance of Lightweight Parts in Mass Production (KROLL L., CZECH A., WALLASCH R.), pp. 42-55
o article: Accuracy of Work Tool Position Measurement by Means of a Drilling Monitoring System (SIWULSKI T.), pp. 56-66
o article: Machine Vision Detection of the Circular Saw Vibrations (SANDAK J., ORLOWSKI K.A.), pp. 67-77
o article: Method for Predicting the Accuracy of Rotational Elements Measurements Using the Five-Axis Coordinate Measuring System (GASKA P., GRUZA M., HARMATYS W., GASKA A., SLADEK J.), pp. 78-86
o article: Extension of a Phase Transformation Model for Partial Hardening in Hot Stamping (HART-RAWUNG T., BUHL J., BAMBACH M.), pp. 87-97
o article: Comparison of Classification Ability Indices of Parameters Characterizing the Stereometric Features of Technical Surfaces (ROZANSKI R.), pp. 98-106

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© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

SIMULATION FOR INSTABLE FLOATING OF HYDRODYNAMIC GUIDES DURING ACCELERATION AND AT CONSTANT VELOCITY

Yingying ZHANG¹, Volker WITTSTOCK¹, Matthias PUTZ^1,2
1Chemnitz University of Technology, Faculty of Mechanical Engineering, Professorship for Machine Tools and Forming Technology, Chemnitz, Germany
²Fraunhofer Institute for Machine Tools and Forming Technology IWU, Chemnitz, Germany

Abstract

High speeds and the resulting hydrodynamic pressure lead to significant floating of the linear guides. During this movement, the floating behaviour shows phenomena that can be explained by the Reynolds equation. This paper presents a dynamic model of the floating behaviour, which adds tribological approaches to the common Reynolds equationsince the floating behaviour does not only depend on the speed, but also on numerous other conditions. This developed simulation method is based on the use of finite difference elements and was implemented using Simulink and Matlab, allowing flexible implementation of further influences such as lubrication cycles and geometry of the sliding surface. After adapting the simulation model and determining the parameters, the calculated floating behaviour corresponds well with the experimental results.

Author Keywords :

dynamic model, instable floating, adaptive FE simulation hydrodynamic guides

© Copyright by Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

IN-PROCESS CONTROL WITH A SENSORY TOOL HOLDER TO AVOID CHATTER

Friedrich BLEICHER¹, Paul SCHÖRGHOFER¹, Christoph HABERSOHN^1
1IFT - Institute for Production Engineering and Laser Technology, TU Wien, Austria

Abstract

Hydro-, steam- and gas- turbines, aircraft components or moulds are milled parts with complex geometries and high requirements for surface quality. The production of such industry components often necessitates the use of long and slender tools. However, instable machining situations together with work pieces with thin wall thickness can lead to dynamic instabilities in the milling processes. Resulting chatter vibrations cause chatter marks on the work piece surface and have influence on the tool lifetime. In order to detect and avoid the occurrence of process instabilities or process failures in an early stage, the Institute for Production Engineering and Laser Technology (IFT) developed an active control system to allow an in-process adaption of machining parameters. This system consists of a sensory tool holder with an integrated low cost acceleration sensor and wireless data transmission under real time conditions. A condition monitoring system using a signal-processing algorithm, which analyses the received acceleration values, is coupled to the NC- control system of the machine tool to apply new set points for feed rate and rotational speed depending on defined optimisation strategies. By the implementation of this system process instabilities can be avoided.

Author Keywords :

adaptive control, condition monitoring, chatter

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

DEVELOPMENT OF AN AUTOMATED ASSEMBLY PROCESS SUPPORTED WITH AN ARTIFICIAL NEURAL NETWORK

Paul BOBKA¹, Jakob HEYN¹, Jann-Ole HENNINGSON¹, Martin RÖMER¹, Thomas ENGBERS¹, Franz DIETRICH ¹, Klaus DRÖDER^1
1Technische Universität Braunschweig, Institut für Werkzeugmaschinen und Fertigungstechnik (IWF), Braunschweig Germany

Abstract

A central problem in automated assembly is the ramp-up phase. In order to achieve the required tolerances and cycle times, assembly parameters must be determinedby extensive manual parameter variations. Therefore, the duration of the ramp-up phase represents a planning uncertainty and a financial risk, especially when high demands are placed on dynamics and precision. To complete this phase as efficiently as possible, comprehensive planning and experienced personnel are necessary. In this paper, we examine the use of machine learning techniques for the ramp-up of an automated assembly process. Specifically we use a deep artificial neural network to learn process parameters for pick-and-place operations of planar objects. We describe how the handling parameters of an industrial robot can be adjusted and optimized automatically by artificial neural networks and examine this approach in laboratory experiments. Furthermore, we test whether an artificial neural network can be used to optimize assembly parameters in process as an adaptive process controller. Finally, we discuss the advantages and disadvantages of the described approach for the determination of optimal assembly parameters in the ramp-up phase and during the utilization phase.

Author Keywords :

assembly, machine learning, neural network,industrial robot

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

MANUFACTURING AND QUALITY ASSURANCE OF LIGHTWEIGHT PARTS IN MASS PRODUCTION

Lothar KROLL¹, Adam CZECH¹, Rainer WALLASCH^1
1Department of Lightweight Structures and Polymer Technology, Faculty of Mechanical Engineering, Chemnitz University of Technology, Chemnitz, Germany

Abstract

Production-related preliminary damage and residual stresses have significant effects on the functions and the damage development in fiber composite components. For this reason, it is important, especially for the safety-relevant components, to check each item. This task becomes a challenge in the context of serial production, with its growing importance in the field of lightweight components. The demand for continuous-reinforced thermoplastic composites increases in various industrial areas. According to this, an innovative Continuous Orbital Winding (COW) process was carried out within the framework of the Federal Cluster of Excellence EXC 1075 "MERGE Technologies for Multifunctional Lightweight Structures". COW is aiming for mass-production-suited processing of special semi-finished fiber reinforced thermoplastic materials. This resource-efficient and function-integrated manufacturing process contains a combination of thermoplastic tape-winding with automated thermoplastic tape-laying technology. The process has a modular concept, which allows implementing other special applications and technologies, e.g. integration of different sensor types and high-speed automated quality inspection. The results show how to control quality and improve the stability of the COW process for large-scale production. This was realized by developing concepts of a fully integrated quality-testing unit for automatic damage assessment of composite structures. For this purpose, the components produced in the COW method have been examined for imperfections. This was performed based on obtained results of non-destructive or destructive materials testing.

Author Keywords :

process control, fiber reinforced plastic, quality assurance

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

ACCURACY OF WORK TOOL POSITION MEASUREMENT BY MEANS OF A DRILLING MONITORING SYSTEM

Tomasz SIWULSKI^1
1Wroclaw University of Science and Technology, Faculty of Mechanical Engineering, Wroclaw, Poland

Abstract

The article presents examples of test results of an innovative, optical system of tool location identification in a workspace. This system was developed and produced as part of the research carried out in cooperation with KGHM Polska Miedź S.A. The article contains a general description of the system, basic components and the scientific basis underlying the development. The technical parameters of the system are also indicated as well as the ranges of required accuracy of the tool location determination, the achievement of which was a condition for the admission of the project to the implementation stage for operation. Based on the results of tests carried out both on the surface and in underground operation conditions, the project assumptions were confirmed and the system's accuracy ranges were determined. The very promising results obtained clearly indicate the validity of continuing work on the development of the tool location identification system in a wider range of machines.

Author Keywords :

work tool position, monitoring of drilling optical system

© Copyright by, Editorial Institution of the Wroclaw Board of

MACHINE VISION DETECTION OF THE CIRCULAR SAW VIBRATIONS

Jakub SANDAK^1,2, Kazimierz A. ORLOWSKI^3
1Innorenew CoE Renewable Materials and Healthy Environments Research and Innovation Centre of Excellence, Isola, Slovenia
²Trees and Timber Institute CNR-IVALSA, San Michele All'Adige, Italy
³Gdansk University of Technology, Faculty of Mechanical Engineering, Department of Manufacturing Engineering and Automation, Poland

Abstract

Dynamical properties of rotating circular saw blades are crucial for both production quality and personnel safety. This paper presents a novel method for monitoring circular saw vibrations and deviations. A machine vision system uses a camera and a laser line projected on the saw's surface to estimate vibration range. Changes of the dynamic behaviour of the saw were measured as a function of the rotational speed. The critical rotational speed of the circular saw blade as well as the optimal rotational speed of the saw were detected.

Author Keywords :

circular saw blade, vibrations, machine vision system, supervising, critical rotational speed

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

METHOD FOR PREDICTING THE ACCURACY OF ROTATIONAL ELEMENTS MEASUREMENTS USING THE FIVE-AXIS COORDINATE MEASURING SYSTEM

Piotr GASKA¹, Maciej GRUZA¹, Wiktor HARMATYS¹, Adam GASKA¹, Jerzy SLADEK^1
1Laboratory of Coordinate Metrology, Cracow University of Technology, Cracow, Poland

Abstract

The measurements of solids of revolution are one of the most common task in industrial practice. Therefore it is not surprising, that new solutions dedicated to improve accuracy and acceleration of measurements of rotational components are emerging. In this group, the new generation of articulating probing systems (with ability of continuous indexation) is worth mentioning. These probing devices combined with standard CMM forms the five-axis coordinate system. Such solution results in measurements acceleration and also improve measurement repeatability. Studies on this type of probing systems proved that their accuracy depends strongly on the angular orientation of probing system used during measurement. Therefore authors developed model that allows simulation of probing system errors for any orientation. This article describes an attempt to use the model to find the configuration of the probing system that would provide the highest accuracy for rotational elements measurements. The simulation results are compared to the real measurements of standard elements performed on five axis measuring system. Described prediction method could have a beneficial effect on improving the accuracy of measurements and, as a result, on reducing production costs by minimizing the risk of erroneous decision on the conformity of products with their geometric specifications.

Author Keywords :

Laboratory of Coordinate Metrology, Cracow University of Technology, Cracow, Poland

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

EXTENSION OF A PHASE TRANSFORMATION MODEL FOR PARTIAL HARDENING IN HOT STAMPING

Thawin HART-RAWUNG¹
Johannes BUHL¹, Markus BAMBACH^1
1Chair of Mechanical Design and Manufacturing, Brandenburg University of Technology Cottbus-Senftenberg, Cottbus, Germany

Abstract

The quality of predicted microstructural and mechanical properties in hot stamping simulations relies considerably on the material model. Many researchers studied the effect of the plastic deformation on the phase transformation of the most commonly used hot stamping steel 22MnB5, and proved that the deformation applied at high temperature promotes the formation of ferrite, pearlite and bainite. This behaviour has to be integrated into materials modelling. In this study, the effect of pre-strain on the phase transformation of the material is considered. The specimens are heated to austenitization temperature, isothermally deformed at 700 °C, and quenched down to room temperature. The phase fractions and the temperature-dilatation behaviour obtained from the experiments are used to calibrate the material model. By using the experimental data obtained from dilatometer testing, the accuracy of the material model is evaluated. Additionally, an attempt to predict the results between the tested data points by using interpolation was made and compared with the simulation results.

Author Keywords :

coefficient of thermal expansion, phase transformation model, hot stamping

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

COMPARISON OF CLASSIFICATION ABILITY INDICES OF PARAMETERS CHARACTERIZING THE STEREOMETRIC FEATURES OF TECHNICAL SURFACES

Rafal ROZANSKI¹,
¹The Jacob of Paradyż University of Applied Sciences in Gorzów Wielkopolski, Technical Department, Gorzów Wielkopolski, Poland

Abstract

The study examined the relationship between the values of two indices evaluating the classification capacity of parameters characterizing the stereometric features of technical surfaces. The values of 83 3D parameters characterizing the stereometric features for 22 surfaces created in various machining processes were taken into account. The examined surfaces differ significantly in the stereometric characteristics of the surface with the similar value of the St parameter. The variance and the geometric mean of ordered parameter values differences were used as the indices of parameters classification ability. In particular, the existence, type and strength of relationship between the adopted indices were evaluated, and the model of the relationship between the indices was determined using the least-squares method. A comparison of the results obtained with those obtained from the analogous evaluation for 8 types of theoretical distributions of parameter values was also carried out.

Author Keywords :

surface geometric structure, parameter classification ability

CONTENTS

SPONSORING
Issue No.4, 2018 is sponsored by the Ministry of Science
and Higher Education of Poland - funding for DOI

JOURNAL OF MACHINE ENGINEERING

o article: Hybrid Additive and Subtractive Manufacturing Processes and Systems: a Review (GRZESIK W.), pp. 5-24
o article: On the Selection and Assessment of Input Variables for the Characteristic Diagram Based Correction of Thermo-Elastic Deformations in Machine Tools (IHLENFELDT S., NAUMANN Ch., PUTZ M.), pp. 25-38
o article: Comparison of Static and Dynamic Laser Based Positioning Methods for Characterization of CNC Machines (BUDZYN G., RZEPKA J., KALUZA P. ), pp. 39-46
o article: In-Process Monitoring and Analysis of Dynamic Disturbances in Boring and Trepanning Association (BTA) Deep Drilling (STEININGER A., BLEICHER F.), pp. 47-59
o article: Automated Root Cause Analysis of Non-Conformities with Machine Learning Algorithms (MUELLER T., GREIPEL J., WEBER T., SCHMITT R.H.), pp. 60-72
o article: An Effect of Grinding on Microhardness and Residual Stress In 20MnCr5 Following Single-Piece Flow Low-Pressure Carburizing (STACHURSKI W., KRUPANEK K., B JANUSZEWICZ B., ROSIK R., WOJCIK R.), pp. 73-85
o article: Brain-Computer Interface for Control of Electro-Hydraulic Servo Drive (WOS P., DINDORF R.), pp. 86-95
o article: Application of Complex Game-Tree Structures for the HSU Graph in the Analysis of Automatic Transmission Gearboxes (DEPTULA A., PARTYKA M.A.), pp. 96-113
o article: Application Of The Hamming Network To The Classification Of Surfaces Ater Abrasive Machining (LIPINSKI D., TOMKOWSKI R., KACALAK W.), pp. 114-126
o article: Modelling of a Glass Gatherer Robot's ARM with a Frictional Damper (STEMBALSKI M., Pawel PRES., SKOCZYNSKI W., TUREK P.), pp. 127-140

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© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

HYBRID ADDITIVE AND SUBTRACTIVE MANUFACTURING PROCESSES AND SYSTEMS: A REVIEW

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

Abstract

This review paper highlights the hybrid manufacturing processes which integrate the additive and subtractive processes performing on one hybrid platform consisting of the LMD (laser metal deposition) unit and CNC machine tools. In particular, some important rules and advantages as well as technological potentials of the integration of different AM technique and finishing CNC machining operations are discussed and overviewed. Some representative examples such as formation of difficult features around the part periphery, deposition of functional layers and coatings and repair of high-value parts in aerospace industry are provided. Some conclusions and future trends in the implementation of hybrid processes are outlined.

Author Keywords :

hybrid manufacturing, CNC machining, additive machining, laser cladding, repair technology

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

ON THE SELECTION AND ASSESSMENT OF INPUT VARIABLES FOR THE CHARACTERISTIC DIAGRAM BASED CORRECTION OF THERMO-ELASTIC DEFORMATIONS IN MACHINE TOOLS

Steffen IHLENFELDT^1,2, Christian NAUMANN¹, Matthias PUTZ^1
1Fraunhofer Institute for Machine Tools and Forming Technology IWU, Chemnitz, Germany
²Dresden University of Technology, Institute of Machine Tools and Control Engineering, Dresden, Germany

Abstract

It is a well-known problem of milling machines, that waste heat from motors, friction effects on guides and most importantly the milling process itself greatly affect positioning accuracy and thus production quality. An economic and energy-efficient method of correcting this thermo-elastic positioning error is to gather sensor data from the machine tool and the process and to use that information to predict and correct the resulting tool center point displacement using high dimensional characteristic diagrams. On the one hand, the selection of which and how many input variables to use in the characteristic diagrams is critical to their performance. On the other hand, however, there are often a great number of possible variable combinations available and testing them all is practically impossible. This paper will discuss the suitability of many different input variable types and present a new method of input variable selection which will be compared to existing methods and demonstrated on measurements performed on a machine tool.

Author Keywords :

thermal effects, algorithm, machine tool, measurement

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

COMPARISON OF STATIC AND DYNAMIC LASER BASED POSITIONING METHODS FOR CHARACTERIZATION OF CNC MACHINES

Grzegorz BUDZYN¹, Janusz RZEPKA¹, Pawel KALUZA^2
1Wroclaw University of Science and Technology, Faculty of Electronics, Wroclaw, Poland
²Lasertex Co. Ltd, Wroclaw, Poland

Abstract

In the paper we compare the laser based measurements of linear parameters of numerically controlled machines. A new dynamic method of measuring machine positioning is described and compared with the widely used static method. The algorithms of the dynamic method are presented and the comparison results of both methods are shown. It is proven that with the new method the measurement time of linear errors of the CNC machines can be reduced significantly. Additionally the machine wear-out in the linear axes can also be easily and efficiently monitored.

Author Keywords :

laser interferometer, ISO230, machine geometry, positioning measurement

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

IN-PROCESS MONITORING AND ANALYSIS OF DYNAMIC DISTURBANCES IN BORING AND TREPANNING ASSOCIATION (BTA) DEEP DRILLING

Andreas STEININGER¹, Friedrich BLEICHER^1
1TU Wien, Institute for Production Engineering and Laser Technology, Wien, Austria

Abstract

This paper presents an approach to monitor the dynamic disturbances of a BTA (boring and trepanning association) deep drilling system. High length to diameter ratios are the key characteristic of deep drilling processes compared to conventional drilling applications. Since length to diameter ratios of up to 150 for slender tool-boring-bar assemblies are common, the deep drilling process is sensitive to dynamic disturbances such as chatter and whirling vibrations. Whirling vibrations usually effect the shape of the hole and cause holes with several lobes. To gain a deeper understanding of the dynamic state of the process, a sensor application has been developed and was tested in practice. Experimental investigations on BTA deep drilling with continuous multi-sensory monitoring were conducted. The used setup allowed the determination of the frequencies of chatter and whirling vibrations during the cutting process by analysing the logged data using a continuous short-time Fourier transformation (STFT).

Author Keywords :

deep drilling process, chatter,whirling vibrations, multi-sensory monitoring

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

AUTOMATED ROOT CAUSE ANALYSIS OF NON-CONFORMITIES WITH MACHINE LEARNING ALGORITHMS

Tobias MUELLER¹, Jonathan GREIPEL¹, Tobias WEBER², Robert H. SCHMITT¹,
¹Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen, Chair of Production Metrology and Quality Management, Aachen, Germany
²Boeing Research & Technology - Europe

Abstract

To detect root causes of non-conforming parts - parts outside the tolerance limits - in production processes a high level of expert knowledge is necessary. This results in high costs and a low flexibility in the choice of personnel to perform analyses. In modern production a vast amount of process data is available and machine learning algorithms exist which model processes empirically. Aim of this paper is to introduce a procedure for an automated root cause analysis based on machine learning algorithms to reduce the costs and the necessary expert knowledge. Therefore, a decision tree algorithm is chosen. A procedure for its application in an automated root cause analysis is presented and simulations to prove its applicability are conducted. In this paper influences affecting the success of detection are identified and simulated e.g. the necessary amount of data dependent on the amount of variables, the ratio between categories of non-conformities and OK parts as well as detectable root causes. The simulations are based on a regression model to determine the roughness of drilling holes. They prove the applicability of machine learning algorithms for an automated root cause analysis and indicate which influences have to be considered in real scenarios.

Author Keywords :

root cause analysis, machine learning, decision tree, simulation

© Copyright by, Editorial Institution of the Wroclaw Board of

AN EFFECT OF GRINDING ON MICROHARDNESS AND RESIDUAL STRESS IN 20MNCR5 FOLLOWING SINGLE-PIECE FLOW LOW-PRESSURE CARBURIZING

Wojciech STACHURSKI¹, Krzysztof KRUPANEK², Bartlomiej JANUSZEWICZ², Radoslaw ROSIK¹, Ryszard WOJCIK^3
1Institute of Machine Tools and Production Engineering, Lodz University of Technology, Lodz, Poland
²Institute of Materials Science and Engineering, Lodz University of Technology, Lodz, Poland
³The Jacob of Paradies University, Gorzow Wielkopolski, Poland

Abstract

The aim of the experiment described in the paper was to determine the effect of selected conditions of abrasive machining on the size and distribution of microhardness and residual stresses developed in the technological surface layer of flat specimens made of 20MnCr5 steel. The specimens were subjected to single-piece flow low-pressure carburizing (LPC) and high-pressure gas quenching (HPGQ) in a 4D Quenching chamber, in order to achieve the effective case depth of ECD=0.4 mm. This was followed by grinding the specimens with Quantum and Vortex alumina grinding wheels made by Norton. Cooling and lubricating liquid were supplied to the grinding zone in both cases by the flood (WET) method and by the minimum quantity lubrication (MQL) method. The measurements for each specimen were made twice - after the thermo-chemical treatment and after the grinding. Microhardness and residual stress was measured by the X-ray method sin2?. The final part of the article provides an analysis of the measurement results and presents conclusions and recommendations for further studies.

Author Keywords :

vacuum carburizing, single-piece flow, surface grinding, microhardness, residual stress

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

BRAIN-COMPUTER INTERFACE FOR CONTROL OF ELECTRO-HYDRAULIC SERVO DRIVE

Piotr WOS¹, Ryszard DINDORF^1
1Faculty of Mechatronics and Machine Design, Kielce University of Technology, Kielce, Poland

Abstract

The aim of the study was to perform bioelectric signal analysis focusing on its applicability to control of the electro-hydraulic servo drive. The natural bioelectric signals generated by brain,facial muscles and eye muscles read by the NIA (Neural Impulse Actuator) are translated into control commands in the controller of electro-hydraulic servo drive. Bioelectric signals detected by means of special forehead band with three sensors are sent to the actuator box, where they are interpreted as control signals. The test stand was constructed to control of the electro-hydraulic servo drive by means of bioelectric signals generated by the operator. The control signals from the actuator box are transmitted via a wireless network to the controller of electro-hydraulic positioning drive.

Author Keywords :

electro-hydraulic positioning system, biosignal processing, parallel manipulator

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

APPLICATION OF COMPLEX GAME-TREE STRUCTURES FOR THE HSU GRAPH IN THE ANALYSIS OF AUTOMATIC TRANSMISSION GEARBOXES

Adam DEPTULA¹, Marian A. PARTYKA^1
1Opole University of Technology, Faculty of Production Engineering and Logistics, Opole, Poland

Abstract

In the article was discussed the possibility of structures and information systems complex game trees for the analysis of automatic gearboxes. The purpose of modelling an automatic gearbox with graphs can be versatile, namely: determining the transmission ratio of individual gears, analysing the speed and acceleration of individual rotating elements. In a further step, logic tree-decision methods can be used to analyse functional schemes of selected transmission gears. Instead, for graphs that are models of transmission, parametrically acting tree structures can be used. This allows for the generalization and extension of the algorithmic approach, furthermore in the future it will allow further analyses and syntheses, such as checking the isomorphism of the proposed solutions, determining the validity of construction and / or operating parameters of the analysed gears. The game tree structure describes a space of possible solutions in order to find optimum objective functions. There is the connection with other graphical structures which can be graphs in another sense, or even decision trees with node and/or branch coding.

Author Keywords :

automatic transmissions gearboxes, Hsu graph, optimization, game-tree structures, computer analysis

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

APPLICATION OF THE HAMMING NETWORK TO THE CLASSIFICATION OF SURFACES AFTER ABRASIVE MACHINING

Dariusz LIPINSKI¹, Robert TOMKOWSKI², Wojciech KACALAK^1
1Koszalin University of Technology, Faculty of Mechanical Engineering, Koszalin, Poland
²KTH Royal Institute of Technology, Industrial Engineering and Management, Department of Prod. Eng., Sweden

Abstract

The use of artificial neural networks for modelling and inference about surface parameters is a more and more often undertaken research topic. Based on the analysis of the ranges of suitability of surface topography parameters, a variety of different parameters can be observed to identify surfaces with different features and different conditions of use. The issues of surface topography analysis and determination of surface condition after abrasive machining are of fundamental importance. Currently, when assessing the surface intended for interaction with the other surface, it is possible to use many surface evaluation parameters. Assigning the machined surface to the appropriate assessment group, especially in automated quality control systems, requires a preliminary surface classification. In this article Hamming's network was used for the surface classification along with modification of Hamming distance.

Author Keywords :

classification, surface topography, abrasive machining, neural network

© Copyright by, Editorial Institution of the Wroclaw Board of Scientific Technical Societies Federation NOT, Wroclaw 2018 Poland

MODELLING OF A GLASS GATHERER ROBOT'S ARM WITH A FRICTIONAL DAMPER

Marek STEMBALSKI¹, Pawel PRES², Waclaw SKOCZYNSKI¹, Paweł TUREK^1
1Wroclaw University of Technology, Department of Machine Tools and Mechanical Technologies, Wroclaw, Poland
²Instytut Lotnictwa, Warszawa, Poland

Abstract

A numerical model of a friction damper used for damping vibration in glass gatherer robots was described. The damper with a lance was modelled using finite elements. Primary natural frequency of the system was determined. Numerical calculations were performed to determine the best operating parameters of the damper for excitations using a impulse of a force. Results of the damping decrement calculations for the friction damper model with a constant coefficient of friction and for the model, in which the coefficient of friction varied depending on the sliding velocity and the normal pressure occurring at the contact surfaces of the damper's friction rings, were presented. Based on numerical simulations, the values of relative displacements between the damper's friction rings were also determined

Author Keywords :

numerical model, damping vibration, glass gatherer, robot