Structure Improvement and Optimization of Gantry Milling System for Complex Boring and Milling Machining Center

To enhance the efficiency and machining precision of the TX1600G complex boring and milling machining center,a study was conducted on the structure of its gantry milling system.This study aimed to mitigate the influence of factors such as structural quality,natural frequency,and stiffness.The approach employed for this investigation involved mechanism topology optimization.To initiate this process,a finite element model of the gantry milling system structure was established.Subsequently,an objective function,comprising strain energy and modal eigenvalues,was synthesized.This objective function was optimized through multi-objective topology optimization,taking into account certain mass fraction constraints and considering various factors,including processing technology.The ultimate goal of this optimization was to create a gantry milling structure that exhibited high levels of dynamic and static stiffness,a superior natural frequency,and reduced mass.To validate the effectiveness of these topology optimization results,a comparison was made between the new and previous structures.The findings of this study serve as a valuable reference for optimizing the structure of other components within the machining center.

A Study on Comprehensive Modeling for Errors in on-line Measuring System of Machining Center

Based on the theory of multi-body system (MBS), bine’s and huston’s methods are applied to an on-line measuring system of machining center in this paper. Through the study on modeling technique, the comprehensive model for errors calculation in an on-line measuring System of machining center have been built for the first time. Using this model, the errors can be compensated by soft.ware and the measuring accuracy can be enhanced without any more inveSt. This model can be used in all kinds of machining center.

Study of Remote Monitoring and Maintenance Guiding Technique Based on LabVIEW for Machining Centers

The virtual instruments （VIs）, as a new type of instrument based on computer, has many advanced attractive characteristics. This research is based on Vls, and brings condition monitoring and knowledge-based maintenance support together through an integrated （including hate.met, ASP. NET, XML tochnique, Vls） network environme~. Within the enviromnent, machining centers operators, engineers or managers can share real-time data through the browser-based interface and minimize machining centers downtime by providing status monitoring and remote maintenance guiding from service centers.

Hybrid Multi-Object Optimization Method for Tapping Center Machines

This paper proposes a hybrid multi-object optimization method integrating a uniform design,an adaptive network-based fuzzy inference system(ANFIS),and a multi-objective particle swarm optimizer(MOPSO)to optimize the rigid tapping parameters and minimize the synchronization errors and cycle times of computer numerical control(CNC)machines.First,rigid tapping parameters and uniform(including 41-level and 19-level)layouts were adopted to collect representative data for modeling.Next,ANFIS was used to build the model for the collected 41-level and 19-level uniform layout experiment data.In tapping center machines,the synchronization errors and cycle times are important consid-erations,so these two objects were used to build the ANFIS models.Then,a MOPSO algorithm was used to search for the optimal parameter combinations for the two ANFIS models simultaneously.The experimental results showed that the proposed method obtains suitable parameter values and optimal parameter combinations compared with the nonsystematic method.Additionally,the optimal parameter combination was used to optimize existing CNC tools during the commissioning process.Adjusting the proportional and integral gains of the spindle could improve resistance to deformation during rigid tapping.The posi-tion gain and prefeedback coefficient can reduce the synchronization errors significantly,and the acceleration and deceleration times of the spindle affect both the machining time and synchronization errors.The proposed method can quickly and accurately minimize synchronization errors from 107 to 19.5 pulses as well as the processing time from 3,600 to 3,248 ms;it can also shorten the machining time significantly and reduce simultaneous errors to improve tapping yield,there-by helping factories achieve carbon reduction.

Optimization Design for Fixed Table of Gantry Machining Center Based on Sensitivity and Topology Analyses

In order to decrease the deformation and stress and increase the natural frequency of the fixed table,a method of optimization driven by the sensitivity and topology analyses is proposed.The finite element model of the fixed table is constructed and analyzed by using ANSYS software.Based on the results of static analysis and modal analysis,the maximum deformation,the maximum stress,and natural frequencies are obtained.Then,the sensitivity analysis and topology optimization are carried out to find out the parameters to be optimized.The fixed table is reconstructed according to optimal design scheme.In the comparison of the results between original model and the optimized one,the maximum deformation and stress are decreased by 71.73%and 60.27%respectively.At the same time,the natural frequencies from the first mode to the sixth mode are increased by 30.28%,29.57%,29.51%,31.52%,22.19%,and 21.80%,respectively.The method can provide technology guide for the design and optimization of machining structure.

Finite Element Analysis and Optimal Design Based on ANSYS in a XH2408 Gantry Style NC Machining Center

ANSYS, the software of construction analysis, is used to analyze static and dynamic performances of a XH2408 gantry style numerical control （NC） milling machining center and optimize its construction using the finite element method. First, a finite element model is established and the static and dynamic analysis are completed as constraints and loads applied on the finite element model. It is found that both spindle box and gantry are the worst components of assembly in performance. Secondly, the spindle box and gantry are chosen as objects of optimal design separately, aiming to improve their performance. The optimal plans are accomplished on the basis of the minimum volume for the spindle box and the maximum inherent frequency for the gantry subject to the constrains. Finally, the machine tool improved is analyzed statically and dynamically based on the optimal results of the spindle box and gantry. The results show that optimal design with the finite element method increases static and dynamical performances of the XH2408 gantry style numerical control milling machining center and the technique is effective and practical in engineering applications.

Failure Modes of Machining Center in Test Run

To analysis the early failures of machining centers,the failure mode effect and criticality analysis( FMECA) method was used. Based on the failure data collected from production lines in test run,all the failure modes of machining centers were summarized and criticality of all subsystems is figured out. And the process of FMECA was improved. The most critical subsystem was manipulator subsystem. The most critical failure mode was impacted manipulator. Reasons and effect of some important failure modes were analyzed. And some suggestions to solve failures were given.

A Machine Learning-Based Web Application for Heart Disease Prediction

This work leveraged predictive modeling techniques in machine learning (ML) to predict heart disease using a dataset sourced from the Center for Disease Control and Prevention in the US. The dataset was preprocessed and used to train five machine learning models: random forest, support vector machine, logistic regression, extreme gradient boosting and light gradient boosting. The goal was to use the best performing model to develop a web application capable of reliably predicting heart disease based on user-provided data. The extreme gradient boosting classifier provided the most reliable results with precision, recall and F1-score of 97%, 72%, and 83% respectively for Class 0 (no heart disease) and 21% (precision), 81% (recall) and 34% (F1-score) for Class 1 (heart disease). The model was further deployed as a web application.

Dynamic Importance Analysis of Machining Center

As an important part of CNC machine tools,machining center’s reliability,efficiency and accuracy measure the machining level of a CNC machine tool.Therefore,the research on the importance of CNC machine tools is particularly important.However,as a complex mechanical and electrical equipment,the traditional reliability importance analysis method is too simple.In order to solve this problem,this passage proposes to establish the reliability model of each part of the machining center,and then analyze its dynamic importance,which improves the limitation of only reliability importance analysis.Through the analysis the reliability importance and criticality importance,and then rank the result of importance analysis,finally it can get that the ranking results of the key components accord with the fact,so the results can provide support for the importance research of machining center.

Tool wear condition monitoring method of five-axis machining center based on PSO-CNN

The effective monitoring of tool wear status in the milling process of a five-axis machining center is important for improving product quality and efficiency,so this paper proposes a CNN convolutional neural network model based on the optimization of PSO algorithm to monitor the tool wear status.Firstly,the cutting vibration signals and spindle current signals during the milling process of the five-axis machining center are collected using sensor technology,and the features related to the tool wear status are extracted in the time domain,frequency domain and time-frequency domain to form a feature sample matrix;secondly,the tool wear values corresponding to the above features are measured using an electron microscope and classified into three types:slight wear,normal wear and sharp wear to construct a target Finally,the tool wear sample data set is constructed by using multi-source information fusion technology and input to PSO-CNN model to complete the prediction of tool wear status.The results show that the proposed method can effectively predict the tool wear state with an accuracy of 98.27%;and compared with BP model,CNN model and SVM model,the accuracy indexes are improved by 9.48%,3.44%and 1.72%respectively,which indicates that the PSO-CNN model proposed in this paper has obvious advantages in the field of tool wear state identification.

技术为先 实力为本——访Fadal Machining Centers市场和销售部副总监Donald J.Haselton先生

Fadal是全球最大的立式加工中心(VMC)生产商之一,其产品在世界范围内销售。目前,已有超过35000台机器交到了客户的手中。这些设备得到了广泛的应用,尤其是用作模具生产加工的基础设备,更是得到了该领域客户的一致肯定。

Three-dimensional Tool Radius Compensation for Multi-axis Peripheral Milling

Few function about 3D tool radius compensation is applied to generating executable motion control commands in the existing computer numerical control (CNC) systems. Once the tool radius is changed, especially in the case of tool size changing with tool wear in machining, a new NC program has to be recreated. A generic 3D tool radius compensation method for multi-axis peripheral milling in CNC systems is presented. The offset path is calculated by offsetting the tool path along the direction of the offset vector with a given distance. The offset vector is perpendicular to both the tangent vector of the tool path and the orientation vector of the tool axis relative to the workpiece. The orientation vector equations of the tool axis relative to the workpiece are obtained through homogeneous coordinate transformation matrix and forward kinematics of generalized kinematics model of multi-axis machine tools. To avoid cutting into the corner formed by the two adjacent tool paths, the coordinates of offset path at the intersection point have been calculated according to the transition type that is determined by the angle between the two tool path tangent vectors at the corner. Through the verification by the solid cutting simulation software VERICUTwith different tool radiuses on a table-tilting type five-axis machine tool, and by the real machining experiment of machining a soup spoon on a five-axis machine tool with the developed CNC system, the effectiveness of the proposed 3D tool radius compensation method is confirmed. The proposed compensation method can be suitable for all kinds of threeto five-axis machine tools as a general form.

ACCURATE MEASUREMENT OF ROTARY MACHINE AXIS CENTER TRACE

Four methods aiming at measuring rotary machine axis center trace arediscussed in detail. The comparative analysis is made on some aspects such as measurement accuracy,on-machine characteristics, feasibility, practical operation convenience and the integrity ofmeasurement information. In order to simplify measurement, the axis profile error is ignored intraditional condition, while the measurement accuracy will be reduced. The 3-point method that theaxis profile error is firstly separated has better real time character, at the same time, not onlythe axis motion error but also the axis profile error can be measured. All of those information canbe used to diagnose the fault origin. The analysis result is proved to be correct by the experiment.

Micro electrical discharge machining of small hole in TC4 alloy

Aiming at machining deeply small holes in TC4 alloy,a series of experiments were carried out on a self-developed multi-axis micro electrical discharge machining(micro-EDM)machine tool.To improve machining efficiency and decrease relative wear of electrode in machining deeply small hole in TC4 alloy,many factors in micro-EDM,such as polarity,electrical parameters and supplying ways of working fluid were studied.Experimental results show that positive polarity machining is far superior to negative polarity machining;it is more optimal when open-circuit voltage,pulse width and pulse interval are 130 V,5μs and 15μs respectively on the self developed multi-axis micro-EDM machine tool;when flushing method is applied in micro-EDM,the machining efficiency is higher and relative wear of electrode is smaller.

Study on Approach for Computer-Aided Design and Machining of General Cylindrical Cam Using Relative Velocity and Inverse Kinematics

Cylindrical Cam Mechanism which is one of the best eq uipments to accomplish an accurate motion transmission is widely used in the fie lds of industries, such as machine tool exchangers, textile machinery and automa tic transfer equipments. This paper proposes a new approach for the shape design and manufacturing of the cylindrical cam. The design approach uses the relative velocity concept and the manufacturing approach uses the inverse kinematics concept. For the shape desig n, the contact points between the cam and the follower roller are calculated bas ed on relative velocity of which the direction is on the common tangential line, and then the whole shape of cam is determined from transformation of the coordi nate system. For the manufacturing procedures, the location and the orientation of cutter path can be allocated corresponding to the designed shape data. The in tegral NC code for multi-axis CNC machining center is created using the inverse kinematics concept from the data of the location and the orientation of cutter path. As the advantages of the proposed approach, the machine tool is designed t o having an alternative size in fabricating the general cam, while the tool must be fitted to diameter size of the follower in the conventional approach. Finally, CAD/CAM program, "Cylindrical DAM", is developed on C++ lan guage. This program can perform shape design, manufacturing and kinematics simul ation, which can make integral NC code for multi-axis CNC machining center. The proposed method can be applied easily on fields of industries.

Laser Interferometer Based Measurement for Positioning Error Compensation in Cartesian Multi-Axis Systems

Accuracy is one of the most important key indices to evaluate multi-axis systems’ (MAS’s) characteristics and performances. The accuracy of MAS’s such as machine tools, measuring machines and robots is adversely affected by various error sources, including geometric imperfections, thermal deformations, load effects, and dynamic disturbances. The increasing demand for higher dimensional accuracy in various industrial applications has created the need to develop cost-effective methods for enhancing the overall performance of these mechanisms. Improving the accuracy of a MAS by upgrading the physical structure would lead to an exponential increase in manufacturing costs without totally eliminating geometrical deviations and thermal deformations of MAS components. Hence, the idea of reducing MAS’s error by a software-based alternative approach to provide real-time prediction and correction of geometric and thermally induced errors is considered a strategic step toward achieving the full potential of the MAS. This paper presents a structured approach designed to improve the accuracy of Cartesian MAS’s through software error compensation. Four steps are required to develop and implement this approach: (i) measurement of error components using a multidimensional laser interferometer system, (ii) tridimensional volumetric error mapping using rigid body kinematics, (iii) volumetric error prediction via an artificial neural network model, and finally (iv) implementation of the on-line error compensation. An illustrative example using a bridge type coordinate measuring machine is presented.

马扎克五轴加工中心后处理研究及验证

在制造业飞速发展的今天,产品对零件的结构及精度要求越来越高。传统三轴加工中心无法满足零件加工要求,而五轴联动机床能很好适应复杂零件的加工工艺。然而,机床厂家并不会免费提供该设备的专用后处理,这给机床使用人员带来了极大困难,同时也浪费了人力成本和时间成本。这里针对马扎克五轴加工中心,运用Tcl脚本语言在UG/Post环境中编制适合该机床的后处理系统。该系统能有效读取刀位文件,并且按照机床要求生成相应加工程序,该程序能安全有效地运行于马扎克VARIAXIS j-500/5X机床。最后通过加工检测五轴联动机床的S试件证明了该后处理系统的有效性和安全性。

基于Isight的可变角度主轴刀柄机构设计与优化

为实现基于三轴数控加工中心的四轴数控加工功能,文中提出了一种可变角度主轴刀柄机构,其具有低成本的多轴化数控功能升级技术优势。首先,完成可变角度主轴刀柄机构的结构设计,并建立该机构的运动学模型;其次,基于ADAMS∕View建立可变角度主轴刀柄机构的参数化模型,并通过Isight平台搭建多目标优化设计流程,以主动臂平均扭矩、主动臂转角及连杆总长度为优化目标,采用NSGA-Ⅱ算法进行多目标优化设计。数值算例的结果表明:相较于原始方案,优化后主动臂平均扭矩减小了15.5%,连杆总长度减小了11.3%,且机构内各部件在运动中不发生结构干涉。因此,基于Isight平台对可变角度主轴刀柄机构进行多目标优化设计的方法是可行的,优化后的机构具有更加合理的尺寸参数,可最大限度地发挥可变角度主轴刀柄机构的动力性和经济性。

木窗双端铣削加工中心关键机构的设计与研究

针对被动式欧式木窗外框铣削加工效率低、加工精度低和人工劳动强度大等问题,设计一种被动式欧式木窗的双端铣削加工中心,用于被动式欧式木窗外框高效率、高精度铣削加工。通过对木窗铣削工艺的分析,采用计算机辅助设计方法对加工中心结构进行详细设计,利用Solidworks软件对加工中心进行三维建模,基于有限元分析软件对关键支撑零件的强度、刚度进行分析,使用虚拟试验方法验证加工中心的加工效率。研究结果表明,加工中心理论加工效率约为400扇/d,相较于人工加工效率350扇/d,效率提升了14.28%,关键支撑零件的最大应力远小于材料的许用应力,满足使用要求。

基于分组遗传算法的数据中心虚拟机节能映射

近年来,随着人们对云计算业务需求持续增长,数据中心能耗日益增加,由此不仅增加了运营成本,巨大的碳排放对生态环境也产生严重的影响,数据中心节能已成为当前亟须解决的重要难题。对云数据中心的虚拟机放置(Virtual Machine Placement,VMP)进行优化能有效地提高资源利用率,同时,VMP也是减少数据中心能耗的重要技术之一;针对数据中心的能耗感知VMP问题,提出一种基于分组遗传算法的节能算法EEGGA(Energy-Efficient Grouping Genetic Algorithm),算法将节能VMP问题视为装箱问题(Bin Packing Problem,BPP),并应用基于分组编码的遗传算法对其进行求解,通过减少活动物理主机的数量(装箱数量)以实现降低数据中心能耗的目标;在算法迭代过程的交叉和变异等阶段,设计了多种启发优化策略提升子代染色体的适应度,从而提高算法的节能性能和加快迭代收敛的速度;通过仿真实验,在收敛速度和求解性能等方面将提出的算法与传统的节能遗传算法进行对比,实验结果表明:提出的算法能够有效地减少数据中心的能耗,在节能性能和求解收敛速度方面均优于其他算法。