Java Language for Numerical Control Simulation System Research

Java language is widely used in a variety of development platforms to develop all kinds of application software for its simple and efficient.The programming language owning platform independent is adopted to solve the image flicker,sound loading and other issues by the threading technology,multimedia technology,graphics and point by point comparison techniques.Dynamic real⁃time process simulation is implemented and a two⁃dimensional network of CNC machining simulation system is developed while Java applet application is as a carrier.The simulation results show that the system has a friendly interface and fast calculation speed,and platform portability has a certain practicality and application value.

Numerical Controlled Rolling Process of Thick Metal Plate

Thick metal plate rolling process has become more and more important in building a flat roof of drilling on the bottom at sea. This is because not only the product quality requirement higher and higher but also the marketing competition. To improve the process of thick metal plate rolling and to increase productivity a numerical controlled rolling process is developed, which include the process planning, the mathematical model establishment and the numerical control system development. The process is for the 17 000 kN×3 000 mm movable up roller bending machine. According to the machine configuration non-symmetry rolling process is planed. This makes it possible to integrate all the steps of plate shaping up such as end side bending, several times of semi-shape bending and the last shape finishing. Since the process will perform under the numerical controlled condition whole steps of the process are considered can be worked in the automatic cycle. The mathematic model consists of two sections, the theory model and the experience parameters model. Which takes the original plate parameters such as geometry and mechanics, characters of the machine such as the movement limits, tonnage and so on as input and calculates all the parameters needed in process performing. Meanwhile, the mathematic Model is totally adapted to the control system. The numerical control system development scheme is based on all the works above. Here, a system plan is provided. The functional modules and hardware selection, in detail, are introduced. The system software on top level and the controlling software for controller are developed. And some unit techniques in the system such as timer setting, communication between system and controller, video integration, and the ability of resisting impact force are introduced. The process has been used successfully in production for more than two years. Practice approves that the process is robust.

Development of PLC-based Tension Control System

Fiber winding tension is an important factor in the molding techniques of composite material which influences the quality of winding product directly, and the tension control is a key technique in fiber winding techniques. This paper introduces a closed-loop tension control system with the programmable logic controller （PLC） with function modules as its control kernel, the alternating current （AC） servo motor as execute element and the radius-following device to accomplish the real-time radius compensation. The mechanism of the tension control system is analyzed and the numerical model is set up. The compensation technique of the radius of the scroll is analyzed. Experimental results show that the system is well qualified with high control precision and high reaction speed.

A Windows bitmap-based numerically controlled sculpture method and its application

Bitmap （BMP） is a widely used format in image processing. With the combination of the digital image processing and computer numerically controlled （NC） techniques, we developed a bitmap-based NC single-step and multi-dot method. An example was provided to illustrate the application and principle of this bitmap-based method in our newly innovated sandblasting glass NC sculpture system.

NOVEL STRUCTURE FOR DISTRIBUTED NUMERICAL CONTROL

Because of an unexpected signal noise within the network or an unpredictedfault with personal computers (PCs), many problems emerge in the implementation of distributednumerical control (DNC) with PCs-based network. To solve the problems, an industrial solution ofinvolving the field-bus technology in DNC communicating area is provided. A kind of advancedField-bus, named controller area network (CAN), is originally developed to support cheap and rathersimple automotive applications. However, because of its good performance and low cost, it is alsobeing considered in automated-manufacturing and process control environments to interconnectintelligent devices, such as modem sensors and actuators. Recently it creates a new role for CANBusin DNC that brings new thinking to DNC. CAN is used as the network platform for connecting machinetools to share information with each other reliably. Additionally, thanks to also applying of'plug-in' technology and a special interface of hardware, this solution exhibits some highcompatibility with different pedigree numerical control (NC) systems, such as Fanuc, Siemens,Cincinnati and so on. In order to improve CANBus for DNC application, a communicating competitionmodel of the basic CAN protocol, called CC model, is then highlighted. This model is able to satisfythe requirements that different machine tools share the communicating bandwidth fairly when theyrun concurrently. Finally the novel view of the latest advancement in CANBus-based DNC incombination with the manufacturing paradigm is also presented.

A Numerical-analytic Method for Quickly Predicting Springback of Numerical Control Bending of Thin-walled Tube

Springback is one of important factors influencing the forming quality of numerical control （NC） bending of thin-walled tube. In this paper, a numerical-analytic method for springback angle prediction of the process was put forward. The method is based on springback angle model derived using analytic method and simulation results from three-dimensional （3D） rigid-plastic finite element method （FEM）. The method is validated through comparison with experimental results. The features of the method are as follows： （1） The method is high in efficiency because it combines advantages of rigid-plastic FEM and analytic method. （2） The method is satisfactory in accuracy, since the field variables used in the model is resulting from 3D rigid-plastic FEM solution, and the effects both of axial force and strain neutral axis shift have been included. （3） Research on multi-factor effects can be carried out using the method due to its advantage inheriting from rigid-plastic FEM. The method described here is also of general significance to other bending processes.

Bayesian zero-failure reliability modeling and assessment method for multiple numerical control(NC) machine tools

A new problem that classical statistical methods are incapable of solving is reliability modeling and assessment when multiple numerical control machine tools(NCMTs) reveal zero failures after a reliability test. Thus, the zero-failure data form and corresponding Bayesian model are developed to solve the zero-failure problem of NCMTs, for which no previous suitable statistical model has been developed. An expert-judgment process that incorporates prior information is presented to solve the difficulty in obtaining reliable prior distributions of Weibull parameters. The equations for the posterior distribution of the parameter vector and the Markov chain Monte Carlo(MCMC) algorithm are derived to solve the difficulty of calculating high-dimensional integration and to obtain parameter estimators. The proposed method is applied to a real case; a corresponding programming code and trick are developed to implement an MCMC simulation in Win BUGS, and a mean time between failures(MTBF) of 1057.9 h is obtained. Given its ability to combine expert judgment, prior information, and data, the proposed reliability modeling and assessment method under the zero failure of NCMTs is validated.

A high-precision control system for robotic welding positioner

Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controller that based on Fuzzy and PID control method. The results of simulation show that the dynamic and steady performances of the intelligent controller are better than that of single PID or Fuzzy controller. This paper has made a detail theoretical analysis of the constitution design and real-time controlled software and brought up the design and fulfillment method of multi-task real-time control software of high precisely and numerically controlled welding positioner, which has a good result in practice.

Application of Elastic Stiffness Damper with Disc Spring to Numerical Control Punch

The paper aims to analyze the impacts of punch damper stiffness on equipment base and vibration, andintroduce the development and application of a disc spring damper featured hard-soft-hard variable stiffness. Adamper has four damping columns with C-type disc springs whose laminates plate number gradually increases setby set. Compared with its counterparts, this kind of dampers has the advantages of high energy absorption andvibration damping effect, which not only can effectively reduce the vibration of the foundation of punch press,but also prevents the vibration range from increasing. Also, this kind of dampers is of low cost and convenient touse.

Carbon Emission Modeling and Analysis in Manufacturing Process for Numerical Control Machine Tools

Reducing carbon emissions( CEs) is the urgent demand all over the world. In order to realize the low-carbon numerical control( NC) machining, the evaluation model of a part's manufacturing carbon emission with NC machine tools was built by considering the influences of the cutting tool geometrical parameters.The manufacturing CEs were produced by electric power,cutting tools,and cutting fluid consumed in manufacturing process. The parameters of cutting tools affected not only the CEs,but also the machining quality. Then the actual constraint models of the machine performance,machining quality were given in order to optimize the cutting parameters and achieve the low-CEs. Finally,a case was given to analyze the influences of the cutting tool angles on the manufacturing CEs. The results show that the CEs decrease as the rake angle and edge angle increase under the constraints of the machine specifications and machining quality.

Heat regulating strategy in numerical control end milling for hard metal machining

The trend in die/mold manufacturing at present is towards the hard machining at high speed to replace the electron dis- charge machining. Failure forms of the AlTiN-coated micro-grain carbide endmill when used for the machining of JIS SKD61 (HRC 53), a widely used material in die/mold manufacturing, are investigated. The endmill shows a characteristic that tool life decreases greatly due to the chipping when overload occurs or the rapid increase of wear when over-heat accumulation in cutting edges. As a consequence of the investigation, a strategy to regulate heat generation in the end milling process is proposed. This is accomplished by controlling the cutting arc length, i.e. the length of each flute engaging workpiece in a cutting cycle. Case studies on the slot end milling and comer rounding are conducted. The results show that the proposed strategy suggests the optimal tool path as well as the optimal pitch between successive tool paths under the cutting time criterion.

Adaptive explicit Magnus numerical method for nonlinear dynamical systems

Based on the new explicit Magnus expansion developed for nonlinear equations defined on a matrix Lie group, an efficient numerical method is proposed for nonlinear dynamical systems. To improve computational efficiency, the integration step size can be adaptively controlled. Validity and effectiveness of the method are shown by application to several nonlinear dynamical systems including the Duffing system, the van der Pol system with strong stiffness, and the nonlinear Hamiltonian pendulum system.

Specialized Numerical Control Plasma Cutting Machine

The large thermal cutting equipment——The DHG. CNC numerical control plasma cutting machine is produced by The Ha’erbin Welding & Cutting Equipment Co. It specializes in the precise formation and baiting of nonferrous boards and thin carbon steel plates at a high speed. It avoids the disadvantage of flame cutting, which cannot cut nonferrous and thin steel plates.

An Investigation into the Life Cycle Cost of a Typical Computer Numerical Control Machine

This paper relates to a typical computer numerical control (CNC) machine, model FDXNC 128, and analyzes the payoff period quantitatively and forecasts the future maintenance cost and the evaluation of the economic benefit by using Life Cycle Cost (LCC) method and grey theory. The discussion shows conclusions that are beneficial to the production, management, and decision making of the enterprise.

Integrated Systemfor Tube Bending Digital Manufacturing

An integrated CAD/CAPP/CAM system of tube manufacturing based on integration frame is presented. In this system, two kinds of data conventions describing tube shape are presented in tube CAD subsystem, the object-oriented concept and the goal-driven inference mechanism have been applied in the development of the knowledge-based CAPP subsystem and simulation of tube processing under tube bending simulation subsystem is performed based on the tube model＇s piecewise representation. A tube product case is considered to give the application of the integrated system, and the advantages of the system in the use of tube bending are revealed.

OPEN ARCHITECTURE CNC SYSTEM HITCNC AND KEY TECHNOLOGY

Aiming at the characteristics of modularity and reconfigurable in open architecture computer numerical control （CNC） system, the open architecture CNC system, Harbin Institute of Tech- nology computer numerical control （HITCNC）, is researched and manufactured based on the interface standards. The system＇s external interfaces are coincident with the corresponding international standards, and the internal interfaces follow the open modular architecture controller （OMAC） agreement. In the research and manufacturing process, object-oriented technology is used to ensure the openness of the HITCNC, and static programming is applied in the CNC system according to the idea of modularization disassembly. The HITCNC also actualizes real-time and unreal-time modules adopting real-time dynamical linked library （RTDLL） and component object model （COM）. Finite state ma- chine （FSM） is adopted to do dynamically modeling of HITCNC. The complete separation between the software and the hardware is achieved in the HITCNC by applying the SoftSERCANS technique. The application of the above key techniques decreases the programming workload greatly, and uses software programs replacing hardware functions, which offers plenty technique ensures for the openness of HITCNC. Finally, based on the HITCNC, a three-dimensional milling system is established. On the system, series experiments are done to validate the expandability and interchangeability of HITCNC. The results of the experiments show that the established open architecture CNC system HITCNC is correct and feasible, and has good openness.

The Innovation of CNC Machine Interface Based on DNC System

This paper describes the innovation schemes of the interface of a CNC machine which cannot communicate with a computer by a Direct Numerical Control(DNC)interface and the functions of a DNC interface system.One architecture of hardware and software of a practi- cal single-chip computer based on DNC interface system developed by the authors is given. Without any change of the original hardware and software,this DNC interface system has been used to innovate the CNC machine's interface to implement the direct communication between a computer and a CNC machine and to achieve no tape transmission of a part program and ma- chine parameters.It has been demonstrated that this DNC interface system has certain practical values in improving the reliability,efficiency and production management of CNC/NC machine.

NUMERICAL STUDY OF FLOW IN CONICAL DIFFUSER WITH VORTEX GENERATOR JETS

To develop vortex generator jet （VGJ） method for flow control, the turbulence flow in a 14° conical diffuser with and without vortex generator jets are simulated by solving Navier-Stokes equations with k-ε turbulence model. The diffuser performance, based on different velocity ratio （ratio of the jet speed to the mainstream velocity）, is investigated and compared with the experimental study. On the basis of the flow characteristics using computation fluid dynamics （CFD） method observed in the conical diffuser and the downstream development of the longitudinal vortices, attempt is made to correlate the pressure recovery coefficient with the behavior of vortices produced by vortex generator jets.

The Electrical and Mechanical Alignment and Accuracy Detection of Numerial Control Machine Tool

In the work of numerical control reformation of general machine tool, the installation and debugging of machine tool is a crucial part. For the C6132 machine tool, and make the use of electrical and mechanical alignment, parameter adjusting, numerical control lathe accuracy debugging and performance examination has been used to finish a series of tailing in the work of numerical control reformation of general machine tool. In this paper, the detailed process of electrical and mechanical alignment, parameter adjusting, numerical control lathe accuracy debugging and performance examination has been demonstrated, meanwhile, the specific operational approach of these work programs has been discussed. Therefore, the present results provides essential reference and approach for the numerical control reformation of general machine tool.

Importance Analysis on Subsystem of CNC Lathe Based on TOPSIS

An importance analysis model for computer numerical control（CNC）lathe subsystems was proposed.The model was based on technique for order preference by similarity to an ideal solution（TOPSIS）and considered the structure correlation between subsystems and the complete machine,the fault correlation of each subsystem and so on.The model can obtain a comprehensive sequencing of subsystems based on their importance to the complete machine.It lays a theoretical foundation for reliability allocation.