The planning method of tool orientation in the five-axis NC machining is studied. The problem of the existing method is analyzed and a new method for generating the global smoothing tool orientation is proposed by int...The planning method of tool orientation in the five-axis NC machining is studied. The problem of the existing method is analyzed and a new method for generating the global smoothing tool orientation is proposed by introducing the key frame idea in the animation-making. According to the feature of the part, several key tool orientations are set without interference between the tool and the part. Then, these key tool orientations are inter- polated by the spline function. By mapping the surface parameter to the spline parameter, the spline function value is obtained and taken as the tool orientation when generating the CL file. The machining result shows that the proposed method realizes the global smoothing of the tool orientation and the continuity of the rotational speed and the rotational acceleration. It also avoids the shake of the machine tool and improves the machining quality.展开更多
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 fr...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.展开更多
Laser-assisted machining has been considered as a new alternative machining method of difficult-to-cut materials. A laser module with one-axis manipulator is developed to focus on preheating laser beam effectively. Fi...Laser-assisted machining has been considered as a new alternative machining method of difficult-to-cut materials. A laser module with one-axis manipulator is developed to focus on preheating laser beam effectively. First of all, the thermal characteristic analysis was performed to verify the importance of laser module location. Laser module should be moved within 1 mm. Analysis conditions of three positions in driving range of the one-axis manipulator are selected. And a C coupling is used as a connection device for spindle and laser module. An initial model has one C coupling, and the number of C coupling has been increased from 1 to 2 in an improved model. And the analysis is carried out again for the one-axis manipulator. The results of the static analysis, the maximum displacement and the maximum stress are decreased by 22% and 11%, respectively, for the improved model when the laser module is located at farthest away from the spindle unit. As a result of the modal analysis, the first natural frequency mode is increased by 13%, 18% and 12% at these positions of the improved model, respectively. The harmonic analysis of the improved model was performed by analyzing the results of the modal analysis. The maximum deformation was 0.33 mm in driving unit at 222 Hz. And the maximum compliance of the ISO axis direction was 0.23 mm/N. Finally, the one-axis manipulator has been fabricated successfully using the analysis result.展开更多
The amount of material must be removed away to produce the final product should minimize, excess stock will increase not only the material cost, but also processing cost, fixture cost, tooling cost, and increases mach...The amount of material must be removed away to produce the final product should minimize, excess stock will increase not only the material cost, but also processing cost, fixture cost, tooling cost, and increases machine cycle times. Noticing in recent years that the world is running out of mineral resources, and the price of engineering materials will continually rise in the future, the percentage of the cost of manufactured part that is due to the cost of materials is also rising. This paper proposed a variant CAPP system for rotational parts based on the concept of group technology, this system accepts part features characteristics code number as an input and provides operation details for manufacturing route with the suitable primary processes required to produce the blank work piece as an output.展开更多
Traditional MEMS （microelectromechanical system） design methodology is not a structured method and has become an obstacle for MEMS creative design. In this paper, a novel method of mask synthesis and verification fo...Traditional MEMS （microelectromechanical system） design methodology is not a structured method and has become an obstacle for MEMS creative design. In this paper, a novel method of mask synthesis and verification for surface micro-machined MEMS is proposed, which is based on the geometric model of a MEMS device. The emphasis is focused on synthesizing the masks at the basis of the layer model generated from the geometric model of the MEMS device. The method is comprised of several steps： the correction of the layer model, the generation of initial masks and final masks including multi-layer etch masks, and mask simulation. Finally some test resuhs are given.展开更多
This article describes experimental evaluations of the authors＇ previous studies on the knowledge-based system （KBS） aimed at capturing and managing CNC （Computer Numerical Control） operator knowledge. The propos...This article describes experimental evaluations of the authors＇ previous studies on the knowledge-based system （KBS） aimed at capturing and managing CNC （Computer Numerical Control） operator knowledge. The proposed KBS follow thinking steps of CNC operators when they assess machining parameters described in the CAM （Computer Aided Manufacturing） file before proceeding to CNC machining processes. Also, the decision support system equipped with expert system （ES） has been proposed to realize efficient knowledge capturing system and effective usability of captured knowledge, and to recommend actions and decisions. From the viewpoint of providing useful information, the KBS should be aware of context or constraints in which the user has to deal with. In this study, the usefulness of DSS （Decision Support System） and ES is experimentally evaluated using real cases. Comparing the results of the testing participants with and without the DSS and ES, the effectiveness and usefulness were demonstrated. In addition, it was shown that the proposed system is also useful to narrow the discrepancies between CAM and CNC operators, focusing on CNC milling operations.展开更多
The design and developmental steps for an auxiliary machining module utilizing a database framework are discussed in this work to contribute to an improvement in workshop operations. The underlining objective is for t...The design and developmental steps for an auxiliary machining module utilizing a database framework are discussed in this work to contribute to an improvement in workshop operations. The underlining objective is for the provision of easily accessible and applicable machining operations data to enable and improve job accuracy and conformity to industrial standards. The design of the database for the decision support system is based on a relational frame with Microsoft Access Application package and Microsoft Structured Query Language Server, which serves as the back end of the module. A user interface designed on .Net Framework 3.5 and the windows installer 3.1 running on windows XP operating system serve as the software front end. The developed module is to serve as a decision support system for machine tool operations.展开更多
Sacrificial multi-piece molds can be used for producing complex parts. To obtain the optimal design of molds automatically, a multi-objective optimal approach is proposed. Mold pieces number, material utilization and ...Sacrificial multi-piece molds can be used for producing complex parts. To obtain the optimal design of molds automatically, a multi-objective optimal approach is proposed. Mold pieces number, material utilization and partitioning area are taken as the objective functions, and the machinability of each mold piece is taken as constraint condition. Genetic algorithm (GA) is adopted to realize global optimization of partitioning process. Each mold piece in optimal scheme can be manufactured by milling and drilling operations, which reduce the tooling cost and shorten product cycle obviously. Using the proposed approach, mold design can be significantly automated for making complex parts.展开更多
G01 code generated by a computer-aided manufacture （CAM） system is the most common form of tool trajeclory in computer numerical control （CNC） machining. A tool path composed of short line segments has discontinuo...G01 code generated by a computer-aided manufacture （CAM） system is the most common form of tool trajeclory in computer numerical control （CNC） machining. A tool path composed of short line segments has discontinuous tangenc t and curvature, generating large fluctuations of feedrate and acceleration, which in turn produces vibration in a machine tool. To obtain a smooth tool path, many methods on tool-path smoothing have been developed. However, the shortcomings i：1 these methods exist when they are employed in a CNC system. It is difficult to simultaneously to guarantee the following requirements of CNC machining： （1） chord error should be rigidly constrained; （2） G01 points should be interpolated; （3） cur,,ature should be continuous （G2）; （4） machining should be applicable to spatial cases; （5） real-time performance of computaEion is required.Based on these various requirements, this study proposes an interpolation scheme using CUDlC t^ezler curves anu mciuucb illl adjustment strategy to eliminate deficiencies in the tool path. The tool path generated is G2, chord-elror-constrained, G01-point-interpolated, loop-free, and optimized for both stretch and jerk energy. The method is applicable ：o 3D cases and involves only simple algebraic computations. Thus, the algorithm can be applied to real-time CNC machining. A simulation is conducted to validate the efficiency of the algorithm. In addition, an experiment reveals its advantage over Hermite interpola- tion in surface quality and machining efficiency.展开更多
文摘The planning method of tool orientation in the five-axis NC machining is studied. The problem of the existing method is analyzed and a new method for generating the global smoothing tool orientation is proposed by introducing the key frame idea in the animation-making. According to the feature of the part, several key tool orientations are set without interference between the tool and the part. Then, these key tool orientations are inter- polated by the spline function. By mapping the surface parameter to the spline parameter, the spline function value is obtained and taken as the tool orientation when generating the CL file. The machining result shows that the proposed method realizes the global smoothing of the tool orientation and the continuity of the rotational speed and the rotational acceleration. It also avoids the shake of the machine tool and improves the machining quality.
文摘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.
基金Project(2012-0005688) supported by the National Research Foundation of Korea (NRF) Grant funded by the Korea Government (MEST)
文摘Laser-assisted machining has been considered as a new alternative machining method of difficult-to-cut materials. A laser module with one-axis manipulator is developed to focus on preheating laser beam effectively. First of all, the thermal characteristic analysis was performed to verify the importance of laser module location. Laser module should be moved within 1 mm. Analysis conditions of three positions in driving range of the one-axis manipulator are selected. And a C coupling is used as a connection device for spindle and laser module. An initial model has one C coupling, and the number of C coupling has been increased from 1 to 2 in an improved model. And the analysis is carried out again for the one-axis manipulator. The results of the static analysis, the maximum displacement and the maximum stress are decreased by 22% and 11%, respectively, for the improved model when the laser module is located at farthest away from the spindle unit. As a result of the modal analysis, the first natural frequency mode is increased by 13%, 18% and 12% at these positions of the improved model, respectively. The harmonic analysis of the improved model was performed by analyzing the results of the modal analysis. The maximum deformation was 0.33 mm in driving unit at 222 Hz. And the maximum compliance of the ISO axis direction was 0.23 mm/N. Finally, the one-axis manipulator has been fabricated successfully using the analysis result.
文摘The amount of material must be removed away to produce the final product should minimize, excess stock will increase not only the material cost, but also processing cost, fixture cost, tooling cost, and increases machine cycle times. Noticing in recent years that the world is running out of mineral resources, and the price of engineering materials will continually rise in the future, the percentage of the cost of manufactured part that is due to the cost of materials is also rising. This paper proposed a variant CAPP system for rotational parts based on the concept of group technology, this system accepts part features characteristics code number as an input and provides operation details for manufacturing route with the suitable primary processes required to produce the blank work piece as an output.
基金Project supported by the National Natural Science Foundation of China (Nos. 60273057 and 60403049) and the National Basic Re-search Program (973) of China (No. 2002CB312106)
文摘Traditional MEMS （microelectromechanical system） design methodology is not a structured method and has become an obstacle for MEMS creative design. In this paper, a novel method of mask synthesis and verification for surface micro-machined MEMS is proposed, which is based on the geometric model of a MEMS device. The emphasis is focused on synthesizing the masks at the basis of the layer model generated from the geometric model of the MEMS device. The method is comprised of several steps： the correction of the layer model, the generation of initial masks and final masks including multi-layer etch masks, and mask simulation. Finally some test resuhs are given.
文摘This article describes experimental evaluations of the authors＇ previous studies on the knowledge-based system （KBS） aimed at capturing and managing CNC （Computer Numerical Control） operator knowledge. The proposed KBS follow thinking steps of CNC operators when they assess machining parameters described in the CAM （Computer Aided Manufacturing） file before proceeding to CNC machining processes. Also, the decision support system equipped with expert system （ES） has been proposed to realize efficient knowledge capturing system and effective usability of captured knowledge, and to recommend actions and decisions. From the viewpoint of providing useful information, the KBS should be aware of context or constraints in which the user has to deal with. In this study, the usefulness of DSS （Decision Support System） and ES is experimentally evaluated using real cases. Comparing the results of the testing participants with and without the DSS and ES, the effectiveness and usefulness were demonstrated. In addition, it was shown that the proposed system is also useful to narrow the discrepancies between CAM and CNC operators, focusing on CNC milling operations.
文摘The design and developmental steps for an auxiliary machining module utilizing a database framework are discussed in this work to contribute to an improvement in workshop operations. The underlining objective is for the provision of easily accessible and applicable machining operations data to enable and improve job accuracy and conformity to industrial standards. The design of the database for the decision support system is based on a relational frame with Microsoft Access Application package and Microsoft Structured Query Language Server, which serves as the back end of the module. A user interface designed on .Net Framework 3.5 and the windows installer 3.1 running on windows XP operating system serve as the software front end. The developed module is to serve as a decision support system for machine tool operations.
文摘Sacrificial multi-piece molds can be used for producing complex parts. To obtain the optimal design of molds automatically, a multi-objective optimal approach is proposed. Mold pieces number, material utilization and partitioning area are taken as the objective functions, and the machinability of each mold piece is taken as constraint condition. Genetic algorithm (GA) is adopted to realize global optimization of partitioning process. Each mold piece in optimal scheme can be manufactured by milling and drilling operations, which reduce the tooling cost and shorten product cycle obviously. Using the proposed approach, mold design can be significantly automated for making complex parts.
基金supported by the National Science and Technology Major Projects(Grant Nos.2013ZX04007041 and 2012ZX04001012)General Financial Grant from the China Postdoctoral Science Foundation(Grant No.2014M552032)
文摘G01 code generated by a computer-aided manufacture （CAM） system is the most common form of tool trajeclory in computer numerical control （CNC） machining. A tool path composed of short line segments has discontinuous tangenc t and curvature, generating large fluctuations of feedrate and acceleration, which in turn produces vibration in a machine tool. To obtain a smooth tool path, many methods on tool-path smoothing have been developed. However, the shortcomings i：1 these methods exist when they are employed in a CNC system. It is difficult to simultaneously to guarantee the following requirements of CNC machining： （1） chord error should be rigidly constrained; （2） G01 points should be interpolated; （3） cur,,ature should be continuous （G2）; （4） machining should be applicable to spatial cases; （5） real-time performance of computaEion is required.Based on these various requirements, this study proposes an interpolation scheme using CUDlC t^ezler curves anu mciuucb illl adjustment strategy to eliminate deficiencies in the tool path. The tool path generated is G2, chord-elror-constrained, G01-point-interpolated, loop-free, and optimized for both stretch and jerk energy. The method is applicable ：o 3D cases and involves only simple algebraic computations. Thus, the algorithm can be applied to real-time CNC machining. A simulation is conducted to validate the efficiency of the algorithm. In addition, an experiment reveals its advantage over Hermite interpola- tion in surface quality and machining efficiency.
