Continuity control method of cutter posture vector for efficient five-axis machining

During five-axis machining of impeller, the excessive local interference avoidance leads to inconsistency of cutter posture, low quality of machined surface and increase of processing time. Therefore, in order to improve the efficiency of five-axis machining of impellers, it is necessary to minimize the cutter posture changes and create a continuous tool path while avoiding interference. By using an MC-space algorithm for interference avoidance, an MB-spline algorithm for continuous control was intended to create a five-axis machining tool path with excellent surface quality and economic feasibility. A five-axis cutting experiment was performed to verify the effectiveness of the continuity control. The result shows that the surface shape with continuous method is greatly improved, and the surface roughness is generally favorable. Consequently, the effectiveness of the suggested method is verified by identifying the improvement of efficiency of five-axis machining of an impeller in aspects of surface quality and machining time.

Method of triangular mesh modeling in numerical control machining simulation

In the process of numerical control machining simulation,the workpiece surface is usually described with the uniform triangular mesh model.To alleviate the contradiction between the simulation speed and accuracy in this model,two improved methods,i.e.,the local refinement triangular mesh modeling method and the adaptive triangular mesh modeling method were presented.The simulation results show that when the final shape of the workpiece is known and its mathematic representation is simple,the local refinement triangular mesh modeling method is preferred;when the final shape of the workpiece is unknown and its mathematic description is complicated,the adaptive triangular mesh modeling method is more suitable.The experimental results show that both methods are more targeted and practical and can meet the requirements of real-time and precision in simulation.

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.

Discussion on Reverse Design of Components with Complex Curved Surface and Computer Numerical Control Machining

With the continuous development and advancement of science and technology,the work of tool path planning has received extensive attention.Among them,curved surface generation and data processing are the focus of management and design,which necessitate the full application of reverse design of complex curved surface components to complete numerical control processing,effective optimization and upgrading,integration the tasks of point cloud data collection,and point cloud data processing to ensure that the corresponding computer numerical control machining model can exert its actual value.This paper briefly analyzes the basic principles of curved surface reconstruction as well as discusses the reverse design of complex curved components and the experimental processes and results that involved computer numerical control machining,which serves the purpose as reference only.

METHOD FOR SUPPRESSING CUTTING CHATTER IN NUMERICAL CONTROL MACHINE TOOLS

A new method for suppressing cutting chatter is studied by adjusting servo parameters of the numerical control （NC） machine tool and controlling the limited cutting width. A model of the cutting system of the NC machine tool is established. It includes the mechanical system, the servo system and the cutting chatter system. Interactions between every two systems are shown in the model. The cutting system stability is simulated and relation curves between the limited cutting width and servo system parameters are described in the experiment. Simulation and experimental results show that there is a mapping relation between the limited cutting width and servo parameters of the NC machine tool, and the method is applicable and credible to suppress chatter.

Bayesian networks modeling for thermal error of numerical control machine tools

The interaction between the heat source location, its intensity, thermal expansion coefficient, the machine system configuration and the running environment creates complex thermal behavior of a machine tool, and also makes thermal error prediction difficult. To address this issue, a novel prediction method for machine tool thermal error based on Bayesian networks (BNs) was presented. The method described causal relationships of factors inducing thermal deformation by graph theory and estimated the thermal error by Bayesian statistical techniques. Due to the effective combination of domain knowledge and sampled data, the BN method could adapt to the change of running state of machine, and obtain satisfactory prediction accuracy. Ex- periments on spindle thermal deformation were conducted to evaluate the modeling performance. Experimental results indicate that the BN method performs far better than the least squares (LS) analysis in terms of modeling estimation accuracy.

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.

Research on Remote Monitoring and Fault Diagnosis Technology of Numerical Control Machine

Based on the internet technology,it has become possible to complete remote monitoring and fault diagnosis for the numerical control machine.In order to capture the micro-shock signal induced by the incipient fault on the rotating parts,the reso- nance demodulation technology is utilized in the system.As a subsystem of the remote monitoring system,the embedded data acquisi- tion instrument not only integrates the demodulation board but also complete the collection and preprocess of monitoring data from different machines.Furthermore,through connecting to the internet,the data can be transferred to the remote diagnosis center and data reading and writing function can be finished in the database.At the same time,the problem of the IP address floating in the dial-up of web server is solved by the dynamic DNS technology.Finally,the remote diagnosis software developed on the Lab VIEW platform can analyze the monitoring data from manufacturing field.The research results have indicated that the equipment status can be monitored by the system effectively.

Real-Time Data and Visualization Monitoring of Computer Numerical Control Machine Tools Based on Hyper Text Markup Language 5

In order to ensure the safety,quality and efficiency of computer numerical control(CNC)machine tool processing,a real-time monitoring and visible solution for CNC machine tools based on hyper text markup language(HTML)5 is proposed.The characteristics of the real-time monitoring technology of CNC machine tools under the traditional Client/Server(C/S)structure are compared and analyzed,and the technical drawbacks are proposed.Web real-time communication technology and browser drawing technology are deeply studied.A real-time monitoring and visible system for CNC machine tool data is developed based on Metro platform,combining WebSocket real-time communication technology and Canvas drawing technology.The system architecture is given,and the functions and implementation methods of the system are described in detail.The practical application results show that the WebSocket real-time communication technology can effectively reduce the bandwidth and network delay and save server resources.The numerical control machine data monitoring system can intuitively reflect the machine data,and the visible effect is good.It realizes timely monitoring of equipment alarms and prompts maintenance and management personnel.

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.

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.

INTERNET-BASED MACHINING PARAMETER OPTIMIZATION AND MANAGEMENT SYSTEM FOR HIGH-SPEED MACHINING

The theory and its method of machining parameter optimization for high-speed machining are studied. The machining data collected from workshops, labs and references are analyzed. An optimization method based on the genetic algorithm (GA) is investigated. Its calculation speed is faster than that of traditional optimization methods, and it is suitable for the machining parameter optimization in the automatic manufacturing system. Based on the theoretical studies, a system of machining parameter management and optimization is developed. The system can improve productivity of the high-speed machining centers.

A NEW ALGORITHM BASED ON TRIANGULATION FOR 5 AXIS MACHINING OF SCULPTURED SURFACES

NC machining path of sculptured surfaces in CAD/CAM system plays an important role on manufacture. This paper describes a new algorithm for 5 axis machining of sculptured surfaces and the algorithm is interference free. The approach includes: (1) the tesselation of the parametric surfaces into triangles; (2) building topological relations among triangles;(3) 5 axis tool path generation; (4) interference detection and tool position correction.

Data-Driven Anomaly Diagnosis for Machining Processes

To achieve zero-defect production during computer numerical control(CNC)machining processes,it is imperative to develop effective diagnosis systems to detect anomalies efficiently.However,due to the dynamic conditions of the machine and tooling during machining processes,the relevant diagnosis systems currently adopted in industries are incompetent.To address this issue,this paper presents a novel data-driven diagnosis system for anomalies.In this system,power data for condition monitoring are continuously collected during dynamic machining processes to support online diagnosis analysis.To facilitate the analysis,preprocessing mechanisms have been designed to de-noise,normalize,and align the monitored data.Important features are extracted from the monitored data and thresholds are defined to identify anomalies.Considering the dynamic conditions of the machine and tooling during machining processes,the thresholds used to identify anomalies can vary.Based on historical data,the values of thresholds are optimized using a fruit fly optimization(FFO)algorithm to achieve more accurate detection.Practical case studies were used to validate the system,thereby demonstrating the potential and effectiveness of the system for industrial applications.

NC Rough Machining of Sculptured Surface Based on Measured Data

A new method for generating tool paths for rough machining of sculpturedsurface is presented in this paper. The sculptured surface is approximated by a regular mesh ofquadrangular facets. A set of equidistant horizontal planes are assigned to intersect the blank ofmachined part and surface model , resulting in a series of contours, which demarcate the feasiblecutting regions of each layer of material removal. The desired cutter path is computed through NCprogramming and any gouging between the cutter and the part being machined is detected and correctedautomatically. The proposed algorithm successfully solves the problem of layered milling forsculptured surface with nested islands.

A Study of the Movement Path for NC-Electrochemical Machining of an Integral Impeller

Aiming at machining an integral impeller used by an aero-engine by NC-Electrochemical Machining （ NC-ECM） , we first describe the fitting of a distorted blade surface with a ruled surface. Then a four-axis NC-electrochemical machining process is analyzed and the movement of the impeller is studied by using an equivalent open-loop plane motion link, and every program segment＇s feed displacement of three axes is calculated by analytical solution. Through comparing two results which are obtained , respectively, from analytical solution and experimental result, the comparative effectiveness has proved that the analytical solution is useful in calculating the feed displacement. The study is helpful for the programming of the machining process.

Optimization of Numerical Control Program and Machining Simulation Based on VERICUT

In the machining process of large-scale complex curved surface,workers will encounter problems such as empty stroke of tool,collision interference,and overcut or undercut of the workpieces.This paper presents a method for generating the optimized tool path,compiling and checking the numerical control(NC)program.Taking the bogie frame as an example,the tool paths of all machining surface are optimized by the dynamic programming algorithm,Creo software is utilized to compile the optimized computerized numerical control(CNC)machining program,and VERICUT software is employed to simulate the machining process,optimize the amount of cutting and inspect the machining quality.The method saves the machining time,guarantees the correctness of NC program,and the overall machining efficiency is improved.The method lays a good theoretical and practical foundation for integration of the similar platform.

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.

Toward Intelligent Machine Tool

With the development of modern information technology-and particularly of the new generation of artificial intelligence(AI)technology-new opportunities are available for the development of the intelligent machine tool(IMT).Based on the three classical paradigms of intelligent manufacturing as defined by the Chinese Academy of Engineering,the concept,characteristics,and systemic structure of the IMT are presented in this paper.Three stages of machine tool evolution-from the manually operated machine tool(MOMT)to the IMT-are discussed,including the numerical control machine tool(NCMT),the smart machine tool(SMT),and the IMT.Furthermore,the four intelligent control principles of the IMT-namely,autonomous sensing and connection,autonomous learning and modeling,autonomous optimization and decision-making,and autonomous control and execution-are presented in detail.This paper then points out that the essential characteristic of the IMT is to acquire and accumulate knowledge through learning,and presents original key enabling technologies,including the instruction-domain-based analytical approach,theoretical and big-data-based hybrid modeling technology,and the double-code control method.Based on this research,an intelligent numerical control(INC)system and industrial prototypes of IMTs are developed.Three intelligent practices are conducted,demonstrating that the integration of the new generation of AI technology with advanced manufacturing technology is a feasible and convenient way to advance machine tools toward the IMT.