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Journal articles on the topic 'Virtual Machining Tools'
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1
Abdul Kadir, Aini, Xun Xu, and Enrico Hämmerle. "Virtual machine tools and virtual machining—A technological review." Robotics and Computer-Integrated Manufacturing 27, no. 3 (2011): 494–508. http://dx.doi.org/10.1016/j.rcim.2010.10.003.
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Huang, Xue Mei, Li Hong Zhao, and Yong Xiang Tong. "Virtual Machining Environment Construction in Vericut for Process Planning." Applied Mechanics and Materials 668-669 (October 2014): 1629–32. http://dx.doi.org/10.4028/www.scientific.net/amm.668-669.1629.
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Virtual machining environment in Vericut was proposed with purpose of enhancing process planning practice training for undergraduates. Main issues include construction of virtual manufacturing resource library and virtual machining process execution environment for planned process. Virtual manufacturing resource library is composed of virtual and digital models for diverse kinds of machine tools. Type determination and classification principle of machine tools and virtual equipment modeling method in the proposed environment are studied. Virtual machining for particular process by multi setup and cut stock transfer method are defined. The proposed Virtual machining process execution environment provides effective ways for enrolled undergraduates applying machining knowledge in process planning, gaining experience with advanced machine tools and manufacturing technology in industrial world.
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Li, Bai Chun, Hai Jun Fu, Tian Biao Yu, and Wan Shan Wang. "Virtual Manufacturing for Machining Process Monitoring." Advanced Materials Research 482-484 (February 2012): 2243–46. http://dx.doi.org/10.4028/www.scientific.net/amr.482-484.2243.
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This paper presents an overall framework of the machining process monitoring system based on virtual manufacturing and does research on its key technology and validates the system with a engraving machine tool. By using of tabletop virtual reality platform Quest 3D, a virtual environment of the machine tool has been created and the machining simulation combined with VC++ has been realized. It has been proved that the simulation and the actual processing interface of monitoring interface are consistent, and the effect is very good. What's more, Using the network module of the virtual reality platform Quest 3D and the additional functions of the database operation, the communications among the machine tools, the server and the client is finished and the manufacturing process monitoring system based on virtual manufacturing is also realized.
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Soori, Mohsen, and Mohammed Asmael. "MINIMIZATION OF DEFLECTION ERROR IN FIVE AXIS MILLING OF IMPELLER BLADES." Facta Universitatis, Series: Mechanical Engineering 21, no. 2 (2023): 175. http://dx.doi.org/10.22190/fume210822069s.
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The 5-axis CNC machine tools are used for manufacturing free form surfaces of sophisticated parts such as turbine blades, airfoils, impellers, and aircraft components. The virtual machining systems can be used in order to analyze and modify the 5-axis CNC machine tools operations. Cutting forces and cutting temperatures induce deflection errors in thin-walled structures such as impeller blades through machining operations. Thin-walled impeller blades' flexibility can result in machining errors such as overcutting or undercutting. So, decreasing the deflection error during machining operations of impeller blades can achieve the desired accuracy in produced parts. Optimized machining parameters can be obtained to minimize the deflection of machined impeller blades. In terms of precision and efficiency enhancement in component production processes, a virtual machining system is developed to predict and minimize deflection errors of 5-axis milling operations of impeller blades. The deflection error in machined impeller blades is calculated by using finite element analysis. The optimization methodology based on the genetic algorithm is applied to minimize the deflection error of impeller blades in machining operations. To validate the integrated virtual machining system in the study, the impeller is milled by using a 5-axis CNC machine tool. The CMM machine is used in order to measure and analyze deflection error in the machined impeller blades. As a result, by using the developed virtual machining system in the study, accuracy and efficiency in 5-axis milling operations of impellers can be increased.
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Afzeri, Agus Geter E. Sutjipto, R. Muhida, Mohamed Konneh, and Darmawan. "Virtual Simulation and Remote Desktop Interface for CNC Milling Operation." Advanced Materials Research 264-265 (June 2011): 1643–47. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.1643.
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Advanced development of computer network through Internet brings the technology to Manufacturing. Increasing the demand for effectively use of the production facility requires the tools for sharing the manufacturing facility by remote operation of the machining process. This paper introduces the methodology of machining technology for direct remote operation of networked milling machine. The tools including virtual simulation using CAD model, remote desktop protocol and Setup Free Attachment for remote operation of milling process are proposed. Accessing and monitoring of machining operation is performed by remote desktop interface and 3D virtual simulations. Capability of remote operation is supported by an auto setup attachment with a reconfigurable pin type setup free technology installed on the table of CNC milling machine to perform unattended machining process. The system is designed using a computer server and connected to a PC based controlled CNC machine for real time monitoring. A client will access the server through internet communication and virtually simulate the machine activity. The result has been presented that combination between real time virtual simulation and remote desktop tool is enabling to operate all machine tool functions and as well as workpiece setup.
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Vichare, Parag, Xianzhi Zhang, Vimal Dhokia, Wai M. Cheung, Wenlei Xiao, and Lianyu Zheng. "Computer numerical control machine tool information reusability within virtual machining systems." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 4 (2017): 593–604. http://dx.doi.org/10.1177/0954405417708219.
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Virtual machining allows simulation of the machining process by realistically representing kinematic, static and dynamic behaviour of the intended machine tools. Using this method, manufacturing-related issues can be brought to light and corrected before the product is physically manufactured. Machining systems utilised in the manufacturing processes are represented in the virtual machining environment, and there is a plethora of commercial virtual machining software used in the industry. Each software system has a different focus and approach towards virtual machining; more than one system may be needed to complete machining verification. Thus, the significant increase in the use of virtual machining systems in the industry has increased the need for information reusability. Substantial time and money has been put into the research of virtual machining systems. However, very little of this research has been deployed within industrial best practice, and its acceptance by the end user remains unclear. This article reviews current research trends in the domain of virtual machining and also discusses how much of this research has been taken on board by software vendors in order to facilitate machine tool information reusability. The authors present use cases which utilise the novel concept of machining capability profile and the emerging STEP-NC compliant process planning framework for resource allocation. The use cases clearly demonstrate the benefits of using a neutral file format for representing machining capability profiles, as opposed to remodelling and/or reconfiguring of this information multiple times for different scenarios. This article has shown through the use cases that machining capability profiles are critical for representing recourse information from a kinematic, static and dynamic perspective that commercial software vendors can subsequently use. The impact of this on mainstream manufacturing industry is potentially significant as it will enable a true realisation of interoperability.
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Hu, Zi Hua, Jie Mei Liu, Zheng Kuang, and Liang Tang. "Research on High Efficient Virtual Measuring Method for Globoidal Cam Machining Error." Advanced Materials Research 305 (July 2011): 202–9. http://dx.doi.org/10.4028/www.scientific.net/amr.305.202.
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Current methods for measuring Globoidal cam exist these problems: difficulty of measurement of profile machining error, heavy dependency on expensive measuring equipment and low measuring efficiency. In order to solve them, this paper established a high efficient virtual measuring method for globoidal cam machining errors. Based on virtual measuring theory and globoidal cam space engagement theory, and by taking the three-dimensional machining simulation models of the globoidal cam profile as the measured object, the virtual gauge head can do measurement along the planned measuring path. The machining error calculation method was determined according to the degree of geometric interference between virtual gauge head and the surface of machined models. And a virtual measuring system on UG platform for globoidal cam profile machining errors was built by use of Visual C++ 6.0 and UG/Open API secondary development tools. Finally, a virtual measuring experiment was performed for the two kind of machining simulation models generated by generating method and one-side machining method. The experimental results show that the high efficient virtual measuring method for globoidal cam machining error is correct and the virtual measuring system is reliable. On the one hand, an effective method is provided to achieve an efficient, low-cost measurement for globoidal cam profile machining errors in this paper. On the other hand, it has great engineering guiding significance for the actual production and processing of globoidal cam.
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Lee, R. S., and J. N. Lee. "Interference-free tool orientation determination by a virtual enveloping element for five-axis machining of a freeform surface." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 215, no. 12 (2001): 1683–93. http://dx.doi.org/10.1177/095440540121501203.
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In machining freeform surfaces on five-axis machine tools, it is very important to determine the location of the cutting tool. The commercial computer aided design/manufacturing (CAD/CAM) software for five-axis machining often lacks flexibility to specify the appropriate tool orientation and toolpath for surface machining. This paper presents a new methodology for determining feasible tool orientation of a toroidal milling cutter with collision and gouging avoidance in five-axis machining of a freeform surface. To avoid collision and rear gouging, a virtual enveloping element is proposed that is derived from the properties of the local and global surfaces. The set of tool orientations can be found first by confining the cutting tool within the virtual enveloping element. Then, the principal induced normal curvatures between the freeform surface and the cutting tool need to be evaluated to offer the criterion of gouging detection. To achieve the best combination of scallop height and machining efficiency, the contact length is also calculated for various tool orientations. The toolpaths generated by the proposed method are verified through solid cutting simulation and a trial cut on a five-axis machine.
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Wang, Qi, Qing Ming Wang, and Xiao Feng Zhang. "A Real Electronic System to Control Virtual Machine in NC Machining Simulation." Applied Mechanics and Materials 226-228 (November 2012): 2203–6. http://dx.doi.org/10.4028/www.scientific.net/amm.226-228.2203.
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In this study, a system composed of real electrical communication system and virtual machine part has been used on NC machining simulation. By establishing a interface based on socket protocol, communication is established between real CNC systems and virtual machine tools. So, processing information of CNC system can be accurately passed to the virtual machine tools. Virtual machine is driven to work in accordance with the instructions of the CNC system. Experiments show that the system is steady and process is repeatable. With structure diagram of communication based on socket protocol shown, the system can be used to detect the manufacturability of the product design process or debug the electrical equipments more efficiently at low cost. It’s also helpful in testing the reliability of NC code in virtual machining.
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Baek, Seung Yub, Jin Ho Chu, and Sung Taek Jung. "A Study on Fabrication of Ultra-Precision Diamond Tool and Length Optimization for Improving the Stability." Key Engineering Materials 777 (August 2018): 289–93. http://dx.doi.org/10.4028/www.scientific.net/kem.777.289.
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A tool for fabricating micro/nanopatterns was utilized in space optics, virtual reality, augmented reality, and semiconductor industry. Nowadays, demand of manufacturing technique for ultra-precision is continuously increasing virtual reality and augmented reality industry across the board and core technique for manufacturing next generation lens is cutting tool fabricating technique with nanoscale. In particular, tools of micro/nanosize for ultra-precision machining was made by using an ultra-precision grinding, but it was difficult to fabricate tools which have under micro scale. Recently, results of studies with many researchers were pulsed laser ablation, electric discharge machining and precision grinding. However, previous studies are unsuitable in making tools of micro/nanoscale. Due to unique physical properties of diamond, it can be easily controlled by using focused ion beam. The surface properties of the diamond layer are affected because of the amorphous damage caused by the FIB gallium ions collision, implantation and these effects can make to be able to control the geometry of cutting tool. In this study, we carried out in fabricating diamond tools under micro scale by using FIB milling through various process studies and determined in order to optimize the length of unstable tool.
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Zhang, Li Qiang, and Ye Cui Yan. "Virtual Five-Axis Milling of Free-Form Surface-Part I: Process Modeling." Applied Mechanics and Materials 29-32 (August 2010): 424–29. http://dx.doi.org/10.4028/www.scientific.net/amm.29-32.424.
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In free-form surface machining, it is essential to optimize the feedrate in order to improve the machining efficiency. This work is the first of a two part paper on cutting force prediction and feedrate optimization for five-axis milling. Conservative cutting parameters have been mostly used since there was a lack of physical models and optimization tools. Part and tool deflections under high cutting forces may result in poor part quality. The extracted cutter workpiece engagements are used as input to a force prediction model. The predicted cutting forces are shown to be in reasonable agreement with those collection during a roughing operation on a dual blades part.
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Sanz, Alfredo, Ignaciof González, Agustin Javier Castejón, and Jose Leopoldo Casado. "Using Virtual Reality in the Teaching of Manufacturing Processes with Material Removal in CNC Machine-Tools." Materials Science Forum 692 (July 2011): 112–19. http://dx.doi.org/10.4028/www.scientific.net/msf.692.112.
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This paper presents a methodology for the incorporation of a Virtual Reality development applied to the teaching of manufacturing processes, namely the group of machining processes in numerical control of machine tools. The paper shows how it is possible to supplement the teaching practice through virtual machine-tools whose operation is similar to the 'real' machines while eliminating the risks of use for both users and the machines.
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STRYCZEK, Roman, and Wojciech SZCZEPKA. "SIMULATION TESTS OF ADAPTIVE CONTROL STRATEGIES FOR CNC MACHINE TOOLS." Journal of Machine Engineering 19, no. 2 (2019): 73–82. http://dx.doi.org/10.5604/01.3001.0013.2225.
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The issue addressed in the article concerns the current needs and possibilities of computer-aided design of adaptive control strategies in machining processes. A simulative method of selecting the adaptive feed control strategy while rough turning materials difficult to machine, effective and inexpensive in its implementation, based on controlling the load placed on the machine's drives, has been presented. The results of a number of virtual tests of the proposed feed control strategy have been included, while paying particular attention to the stability of the machining process during moments of sudden change in the machining allowance. The obtained results meet the accepted quality indicators of the control algorithm. At the same time, the experiences collected by the author while conducting the tests confirmed the complexity of the issue and the resulting necessity to implement a comprehensive simulation testing program.
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Fortunato, Alessandro, and Alessandro Ascari. "The virtual design of machining centers for HSM: Towards new integrated tools." Mechatronics 23, no. 3 (2013): 264–78. http://dx.doi.org/10.1016/j.mechatronics.2012.12.004.
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Tani, Giovanni, Raffaele Bedini, Alessandro Fortunato, and Claudio Mantega. "Dynamic Hybrid Modeling of the Vertical Z Axis in a High-Speed Machining Center: Towards Virtual Machining." Journal of Manufacturing Science and Engineering 129, no. 4 (2007): 780–88. http://dx.doi.org/10.1115/1.2738097.
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This paper describes the modeling and simulation of the Z axis of a five axis machining center for high-speed milling. The axis consists of a mechanical structure: machine head and electro-mandrel, a CNC system interfaced with the feed drive, and a pneumatic system to compensate for the weight of the vertical machine head. These subsystems were studied and modeled by means of: (1) finite element method modeling of the mechanical structure; (2) a concentrated parameter model of the kinematics of the axis; (3) a set of algebraic and logical relations to represent the loop CNC-Z feed drive; (4) an equation set to represent the functioning of the pneumatic system; and (5) a specific analytical model of the friction phenomena occurring between sliding and rotating mechanical components. These modeled subsystems were integrated to represent the dynamic behavior of the entire Z axis. The model was translated in a computer simulation package and the validation of the model was made possible by comparing the outputs of simulation runs with the records of experimental tests on the machining center. The firm which promoted and financed the research now has a virtual tool to design improved machine-tool versions with respect to present models, designed by traditional tools.
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Fountas, Nikolaos A., Nikolaos M. Vaxevanidis, Constantinos I. Stergiou, and Redha Benhadj-Djilali. "Precision Sculptured Surface CNC Machining Using Cutter Location Data." Key Engineering Materials 686 (February 2016): 224–33. http://dx.doi.org/10.4028/www.scientific.net/kem.686.224.
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Industrial parts with sculptured surfaces are typically, manufactured with the use of CNC machining technology and CAM software to generate surface tool paths. To assess tool paths computed for 3-and 5-axis machining, the machining error is evaluated in advance referring to the parameter controlling the linearization of high-order curves, as well as the scallop yielded as a function of radial cutting engagement parameter. The two parameters responsible for the machining error are modeled and corresponding cutter location data for tool paths are utilized to compare actual trajectories with theoretical curves on a sculptured surface assessing thus the deviation when virtual tools are employed to maintain low cost; whilst ensuring high precision cutting. This operation is supported by applying a flexible automation code capable of computing the tool path; extracting its CL data; importing them to the CAD part and finally projecting them onto the part’s surface. For a given tolerance, heights from projected instances are computed for tool paths created by changing the parameters under a cutting strategy, towards the identification of the optimum tool path. To represent a global solution rough machining is also discussed prior to finish machining where the new proposals are mainly applied.
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Zhang, Li Qiang. "Virtual Simulation and Optimization for 5-Axis Milling Process." Advanced Materials Research 102-104 (March 2010): 754–57. http://dx.doi.org/10.4028/www.scientific.net/amr.102-104.754.
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5-axis milling operations are used in industries such as aerospace, automotive and mold for free-form surface machining. In these process, surface quality and material removal rate are of very important. Conservative cutting parameters have been mostly used since there was a lack of physical models and optimization tools. Part and tool deflections under high cutting forces may result in unacceptable part quality. The overall goal of this research is the integration of geometric and mechanistic models for cutting process simulation and feedrate optimization. The extracted cutter workpiece engagements are used as input to a force prediction model. The model predictions for cutting forces and feedrate optimization are compared and verified by experimental results.
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An, Guo Ping, Zhuang Zhuang Liu, Zhi Feng Liu, Yong Sheng Zhao, and Li Gang Cai. "Research of Gantry Machining Center Assembly Deviation Sensitivity Based on Multi-Body System." Applied Mechanics and Materials 494-495 (February 2014): 365–72. http://dx.doi.org/10.4028/www.scientific.net/amm.494-495.365.
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Heavy duty machine tool has some special points, such as large size, complex structure, long cycle at Installation and commissioning, high requirements assembly processes and so on. Therefore, this paper established a mathematical model to transform the origin parts of the gantry machining center into assembly special form and creates a software as a plug-in for Solidworks based on it, proposes an easy but very practical assembly method based on Multi-body system under virtual environment. This method can calculate assembly deviation caused by manufacturing tolerance very quickly, and bring the sensitivity information clearly. Assembly deviation sensitivity and assembly method proposed in this paper can provide a way for the virtual assembly of heavy-duty CNC machine tools, Thus provide an important theoretical basis to improve the performance of the machine
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Zhang, Lei, Bo Zhang, Lin Ba, and Hang Gao. "The Centerline Position Measuring and Online Machining Compensation of the Rail Base for High-Speed MAGLEV." Materials Science Forum 532-533 (December 2006): 592–95. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.592.
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The precision machining of the rail base for high-speed Magnetically Levitated Trains (MAGLEV) is the precondition for laying the high-quality whole rail and accomplishing the integrative performance test of the train. A new method is advanced to improving the machining precision in this paper. The X and Y coordinates of the cross centers on the rail base for MAGLEV will be obtained through two raster displacement sensors which are perpendicular to each other. So the machining datum position of the rail will be determined. According to the spatial position relationship between the straight movement error of the guideway on the numerical control machine tools and the central line of the rail base for MAGLEV, error compensation will be made to improve the machining precision in the process of the numerical control machining. The mechanism design theory of the measuring system is presented in this paper. On basis of both the design theory and the software platform of LabWindows/CVI, the virtual measurement system for measuring straight movement error of the rail on the numerical control machine tool, which is used to machining the rail base for MAGLEV will be established.
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Xu, Hong Ping, Ling Dong Wu, Yi Wang, and Liang Yi Li. "Kinematics Simulation of Vertical Flange Lathe with Double Machining Tools Based on Virtual Prototype Technology." Applied Mechanics and Materials 101-102 (September 2011): 302–5. http://dx.doi.org/10.4028/www.scientific.net/amm.101-102.302.
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To study the kinematic characteristics of a new designed flange vertical lathe with double machining tools, a virtual prototype model was developed in ADAMS with the help of PRO/E and MechPro, a seamless interface program between both mentioned software. And kinematic and dynamic simulations were carried out. The results of the simulations are consistent with the reality which states that the model was created correctly and the simulations were reliable.
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SUI, XIULIN, IMRE HORVATH, JIATAI ZHANG, and PING ZHANG. "A HIGHER FIDELITY MODELING OF THE CUTTING EDGE OF BALL-END MILLING TOOL." Journal of Advanced Manufacturing Systems 10, no. 01 (2011): 101–8. http://dx.doi.org/10.1142/s021968671100203x.
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Ball-end milling tools have been widely used in machining of complex freeform surfaces. The precision and efficiency of ball-end milling process can be improved by an accurate modeling of the tools, the tools' paths and the machining conditions. However, only rough geometric models have been applied so far, which do not consider the machining conditions and the physical changes. To achieve the best results, an accurate modeling of the cutting edge and the physical behavior of the entire cutter is needed. This paper proposes an articulated model that enumerates both the geometric characteristics and the physical effects acting on the cutting edge-segment of a ball-end milling cutter. The model considers the deformations caused by the milling forces, vibration, spindle eccentricity, together with thermal deformation and wear of the cutter. The mathematical description of the behavior has been transferred into a computational model. The pilot implementation has been tested in a practical application. The first findings show that the proposed theoretical model and implementation provide sufficiently precise information about the behavior of the cutter in virtual simulations; hence it can be the basis of a fully fledged and more efficient planning of milling processes.
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Li, Xiaolei, Canyu Yang, and Wei Li. "Interactive Learning and Application of Virtual Simulation Machining of CNC Machine Tools based on VERICUT." Journal of Physics: Conference Series 2016, no. 1 (2021): 012002. http://dx.doi.org/10.1088/1742-6596/2016/1/012002.
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Shneor, Yair, Vladimir S. Chapsky, and Amir Shapiro. "Virtual verification of 5-axis machine tools based on workpiece accuracy analysis: Software tool instead of expensive machining tests." Procedia Manufacturing 21 (2018): 228–35. http://dx.doi.org/10.1016/j.promfg.2018.02.115.
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Ward, Rob, Burak Sencer, Bryn Jones, and Erdem Ozturk. "Accurate prediction of machining feedrate and cycle times considering interpolator dynamics." International Journal of Advanced Manufacturing Technology 116, no. 1-2 (2021): 417–38. http://dx.doi.org/10.1007/s00170-021-07211-2.
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AbstractThis paper presents an accurate machining feedrate prediction technique by modelling the trajectory generation behaviour of modern CNC machine tools. Typically, CAM systems simulate machines’ motion based on the commanded feedrate and the path geometry. Such approach does not consider the feed planning and interpolation strategy of the machine’s numerical control (NC) system. In this study, trajectory generation behaviour of the NC system is modelled and accurate cycle time prediction for complex machining toolpaths is realised. NC system’s linear interpolation dynamics and commanded axis kinematic profiles are predicted by using finite impulse response (FIR)–based low-pass filters. The corner blending behaviour during non-stop interpolation of linear segments is modelled, and for the first time, the minimum cornering feedrate that satisfies both the tolerance and machining constraints has been calculated analytically for 3-axis toolpaths of any geometry. The proposed method is applied to 4 different case studies including complex machining toolpaths. Experimental validations show actual cycle times can be estimated with > 90% accuracy, greatly outperforming CAM-based predictions. It is expected that the proposed approach will help improve the accuracy of virtual machining models and support businesses’ decision-making when costing machining processes.
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Lee, W. B., C. F. Cheung, J. G. Li, S. To, J. J. Du, and Z. Q. Yin. "Development of a virtual machining and inspection system for ultra-precision diamond turning." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 221, no. 7 (2007): 1153–74. http://dx.doi.org/10.1243/09544054jem491.
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The conventional approach to establish optimal processing conditions in ultraprecision diamond turning is empirical in nature. The achievement of a super mirror finish and submicrometre form accuracy in many current industrial applications still depends much on the experience and skills of the machine operators through trial cutting tests when new materials or new machine tools are used. In this paper, a virtual machining and inspection system (VMIS) is presented for ultra-precision diamond turning. The development of the VMIS aims at creating a virtual manufacturing environment for the optimization of process parameters and evaluating the quality of machined surface through various modelbased simulation modules. The VMIS is validated through a series of practical cutting tests conducted on a two-axis computer numerical control ultra-precision turning machine. The experimental results agree well with the simulated data.
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Wang, Chao, Lin Nan Han, Yuan Yao, Qian Sheng Zhao, and Qing Xi Hu. "Research on Numerical Control Machining Simulation Based on Power Mill and VERICUT." Applied Mechanics and Materials 121-126 (October 2011): 2200–2204. http://dx.doi.org/10.4028/www.scientific.net/amm.121-126.2200.
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To prevent the collision of tools and machine during the process of numerical control processing, reduce the number of cutting experiments and improve the production efficiency, it is a better way by using virtual simulation. This paper based on a mold cavity model of STL files, realized the numerical control programming based on Power Mill, researched the dynamic simulation process based on VERICUT, and at last verified the correctness and practicability of VERICUT simulation result by physical processing, which provided a reliable reference for physical machining.
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Balijepalli, Arvind, and T. Kesavadas. "Value-Addition of Haptics in Operator Training for Complex Machining Tasks." Journal of Computing and Information Science in Engineering 4, no. 2 (2004): 91–97. http://dx.doi.org/10.1115/1.1739240.
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This paper presents a haptic simulator based on a force model that renders precise and crisp force feed back for a range of applications such as grinding, polishing and deburring of metals using an abrasive hand-grinding tool. Many skill based manufacturing and medical applications require a human operator to use grinding tools to impart force to remove material from a surface that may have rough texture or asperities. This paper describes the design, implementation and evaluation of this proposed system. First a force model is presented to compute forces resulting from grinding tool work piece interface. Next an image based 3D Terrain modeling algorithm is developed to simulate the details of work piece topology. To create sensation of metal removal during the grinding processes, a dynamic texture modification algorithm is developed to provide realistic virtual simulation of polishing process. Finally human subject tests are carried out to test the effectiveness of the simulator. The skill sets required for grinding operations are usually learned through practice. The grinding simulator presented here is a step towards using haptics to perfect this skill that is otherwise hard to learn quickly.
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Patel, Kaushalendra V., Krzysztof Jarosz, and Tuğrul Özel. "Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel." Journal of Manufacturing and Materials Processing 5, no. 3 (2021): 65. http://dx.doi.org/10.3390/jmmp5030065.
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Physics-based process simulations have the potential to allow virtual process design and the development of digital twins for smart machining applications. This paper presents 3D cutting simulations using the finite element method (FEM) and investigates the physical state variables that are fundamental to the reduction in cutting forces, friction, and tool wear when micro-textured cutting tools are employed. For this goal, textured cemented carbide cutting tool inserts are designed, fabricated, and tested in the orthogonal dry cutting of a nickel-chromium-molybdenum alloy steel. Cutting forces and friction coefficients are compared against the non-textured tool, revealing the effects of texture parameters. Chip flow over the textured tool surface and process variables at the chip-tool contact are investigated and compared. The results reveal the fundamental sources of such improvements. Archard’s wear rate as a composition of process variables is utilized to compare experimental and simulated wear on the textured cutting tools. The effects of texture and cutting conditions on tool wear and adhesion characteristics are further discussed on the simulation results with experimental comparisons. It was found that the results obtained from these simulations provide further fundamental insights about the micro-textured cutting tools.
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Cheng, Hsin Yu, and Yung Chou Kao. "Studies on the Exchangeability of Different APT Interpreters for 5-Axis Machine Tool Applications." Applied Mechanics and Materials 284-287 (January 2013): 1924–28. http://dx.doi.org/10.4028/www.scientific.net/amm.284-287.1924.
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Generally, the NC format is the description for the positioning and/or the movement of its linear and rotary axes. As the multi-axis machine tools have a variety of configurations, their NC codes are not exchangeable. This issue leads to some inconvenience and confounding in the manufacturing processing schedule. Furthermore, when the specifications of tool such as length, diameter or shape are reset, the NC program must be regenerated accordingly. That is to say, the exchangeability of NC program among different five-axis machine configurations is an important issue in making better usage of industrial five-axis machine tools for efficient applications. An APT program records the tool path, tool vector and cutting information, etc. In particular, the recent development of APT format can provide the capability recording the motion posture of the tool such as the tool orientation, the position and its normal vector of the tool contact point. Therefore, it can solve the problems of the exchangeability for the different machine tools as well as the online resetting of tool specifications, even the tool posture. In this paper, a new method was proposed to interpret the APT code into tool movement data including toolpath, location, tool orientation, the contact point and its contact vector, etc., which can be applied to the conversion of different NC codes, or be connected to the controller of the machine tool so as to proceed the interpolation calculation for directly machining control. Moreover, the application scope can be extended to the verification of machining and to drive a virtual machine tool for previewing. Since the APT format varies according to different CAD/CAM systems, a common intermediate interchange standard (CMIS) was proposed, designed and verified in this paper as a feasible solution for the exchangeability of different APT formats. The process of the proposed method includes interpreting a variety of APT program into a common standard format, and then transforming this intermediate standard code into various NC programs for the corresponding machine configurations. An example was used to demonstrate how to convert an APT generated by CATIA software into intermediate code for a Table-Table five-axis machine tool with two rotary axes attached on table (XYZAC configuration). As the APT contains the definition of inclined plane, so the homogeneous coordinate transformation was adopted to transform the coordinate system of the inclined plane into the work coordinate system; it was further transformed into the corresponding NC program via an inverse kinematics transformation. This example has shown the feasibility of the method proposed. Moreover, the research can be applied not only to the exchangeability of different APT format but also to the other related applications such as the verification of machining error and the drive of virtual machine tool.
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Kobori, Syuhei, and Koichi Morishige. "Development of Operation Interface for Machine Tool Using 6-DOF Haptic Device - Guidance of Tool Movement Using Force Sense." Key Engineering Materials 516 (June 2012): 337–42. http://dx.doi.org/10.4028/www.scientific.net/kem.516.337.
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In the previous report, the operation interface for multi-axis controlled machine tools was developed by using the haptic device that is used in the field of virtual reality and it was changed from a haptic device with 3-DOF to that with 6-DOF. In order to improve the system, more useful functions should be added. In this report, the function to guide the tool in consideration of the tools characteristics is developed. The square end mill cannot cut at its bottom part. So, when the bottom part contacts the removal shape, the square end mill should be guided into a posture contacting at the side part by the force sense. The experiment supposed that the machining of the curved surface had been done. In the case of using the developed function, the number of contacts at the bottom part of the tool was decreased. As a result, the usefulness of the developed function was confirmed.
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Планковський, Сергій Ігорович, Євген Володимирович Цегельник, Віталій Борисович Минтюк, Сергій Миколайович Задорожний та Володимир Вікторович Комбаров. "МЕТОД ВІРТУАЛЬНОГО БАЗУВАННЯ ДЕТАЛЕЙ З ФОРМОЮ, НАБЛИЖЕНОЮ ДО ФОРМИ ЗАГОТОВОК". Aerospace technic and technology, № 4 (28 серпня 2020): 74–82. http://dx.doi.org/10.32620/aktt.2020.4.09.
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The subject matter of the article is the processes of virtual localization of near shape parts during adaptive machining. The aim is to develop an effective method for finding the starting location of a CAD model of a part with virtual localization inside a point cloud obtained by laser scanning of a workpiece. The task is to formalize the procedure for starting positioning of the part model as the first stage of the virtual localization process. The second stage for final localization proposed to use iterative algorithms with the objective function which is sensitive to the intersection of the surface parts and the workpiece. In solving the problem the starting position used tools available in today's CAD packages and 3D scanning tools. The methods used are the methods of matrix algebra, in particular, the methods for finding the main central moments of inertia of three-dimensional objects based on the tensor of inertia. The following results were obtained. When calculating the inertia tensor components is proposed to use three-dimensional scanning data of workpiece and geometrical data of part obtained from the CAD system. The result is an algorithm starting location of CAD model in the virtual localization, which in the case of blanks with oversize close to uniform can provide enough current location parts for adaptive machining tasks. It is shown that to minimize computational errors and to ensure satisfactory accuracy of localization proposed algorithm can require several iterations of the shift vector search model. Conclusions. The scientific novelty of the results obtained is as follows: in contrast to the previously used approaches, when solving the problem of virtual localization for the starting position, using the condition of coincidence of the centers of the weight of thin shells coinciding with the surfaces of the workpiece and the part, it was proposed to additionally ensure the alignment of the main central axes of inertia of these shells, which, in the case of near shape blanks, provides a positioning accuracy that may not require additional iterative procedures.
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Kakinuma, Yasuhiro, and Daisuke Kono. "Special Issue on Self-Optimizing Machining Systems." International Journal of Automation Technology 16, no. 2 (2022): 125. http://dx.doi.org/10.20965/ijat.2022.p0125.
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The concept of Self-Optimizing Machining Systems (SOMS) has been proposed against the background of Industry 4.0 and the Digital Twin concept, based on cyber-physical systems. In order to improve manufacturing productivity, quality, and efficiency, each component technology related to the machining process, such as CAD/CAM, process modeling/simulation, process monitoring/control, and workpiece assessment, as well as the machine tools themselves, has been developed independently to date. However, series of processes, including the interactions among these component technologies, have finally determined the machining performance and the quality of the products. SOMS deals with the information links among these components comprehensively and plays the important role of combining these links and functionalities to optimize the overall machining system. Nevertheless, an intensive implementation and combination of these technologies has yet to become state-of-the-art in industry, while further research and development for SOMS is required for Industry 4.0 and Digital Twin. This special issue focuses on the research trends of SOMS, especially the interaction links among machine tools, process monitoring, and work assessment. From researchers who are active on the front lines of manufacturing engineering, the latest achievements related to the development of SOMS are presented in 6 papers. On one hand, the development of sensor-integrated components is indispensable for SOMS to monitor the status of a process and feed it back to a related component in order to control the machining process and its environment. On the other hand, it can be said that visual simulation, virtual metrology, and other epoch-making, on-machine technologies for evaluating machined surfaces, as well as process optimization based on machined surface information, are strongly required. We hope this special issue will contribute to future research and development for researchers and engineers in the field of manufacturing and machining systems.
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Beamud González, Elena María, Pedro Jose Núñez López, Eustaquio García Plaza, David Rodríguez Salgado, Alfonso González González, and Justo García Sanz-Calcedo. "Reverse Engineering Applied to the Teaching of Computer Aided Manufacturing." Materials Science Forum 903 (August 2017): 120–27. http://dx.doi.org/10.4028/www.scientific.net/msf.903.120.
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One of the main shortcomings of individualized training in the use of computer aided design (CAD), and computer aided manufacturing (CAM) tools is that students lack a sound and broad understanding of the type of tools, and their specific and integrated applications in industrial manufacturing. This study aimed to design an integrated curricular training programme in computer aided tools for the design and manufacture of mechanical components based on reverse engineering techniques. By using real products that students can see and touch, a scanned copy is obtained for subsequent reconstruction into a virtual three-dimensional model using the software for optimizing the point cloud, meshing, and creating both the surface and solid. Once the virtual three-dimensional model has been obtained, it is exported to a solid modelling CAD (3D-CAD) software for modification according to the geometrical requirements. The next step is for students to manufacture a component using rapid prototyping techniques, which allow them to visualize, analyse, and inspect a component to optimize its design. The use of computer aided manufacturing software enables students to design and plan machining operations virtually to obtain a computer numeric control (CNC) program for the manufacture of a component with a CNC machine tool. Finally, students perform a quality control of the component by employing a range of measurement techniques. This training program is integrated into the subjects of the mechanical engineering degree, where students can work with these tools in line with an intergraded curriculum.
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Stavropoulos, Panagiotis, Thanassis Souflas, Nikolas Porevopoulos, and Harry Bikas. "Application of virtual engineering tools to support design optimization: a case study on a cryogenic machining system." Procedia CIRP 100 (2021): 181–86. http://dx.doi.org/10.1016/j.procir.2021.05.052.
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Stănăşel, Iulian, Florin Blaga, Traian Buidoş, and Dan Crăciun. "Reverse engineering and CAD-CAM approach for manufacturing of spare parts. Case study." MATEC Web of Conferences 184 (2018): 03004. http://dx.doi.org/10.1051/matecconf/201818403004.
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Reverse engineering represents a method to retrieve information from an existing product, information which are then used for designing a new product or to reproduce it in order to make spare parts. In this paper is presented a case study on making a spare part of complex shape from a worn part. There are presented the stages of acquisition of data by scanning, the use of reverse engineering for the realization of the 3D model, the virtual manufacturing and then the machining of the workpiece CNC machine tools.
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Muszyńska, Magdalena, Dariusz Szybicki, Piotr Gierlak, Krzysztof Kurc, and Andrzej Burghardt. "The Use of VR to Analyze the Profitability of the Construction of a Robotized Station." Advances in Manufacturing Science and Technology 44, no. 1 (2020): 32–37. http://dx.doi.org/10.2478/amst-2019-0005.
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AbstractThe development of software applications and the use of VR (Virtual Reality) techniques allow to improve the company’s financial result. The construction of models of robotic stations with robots using Virtual Robot technology allows to determine the time of the machining process. It allows its optimization through the selection of accelerations, tools, tooling strategies, and so on. Determining the time of a technological operation translates into savings. This allows you to decide on the purposefulness of the investment. In addition, modern software add-ons, for example, Signal Analyzer in RobotStudio, allow you to monitor the electricity consumption of a robotic station. The article presents a solution showing how, based on the construction of digital models and the use of VR, we can conclude about the profitability of the investment.
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Ding, Yabin, Wei Guo, Xianping Liu, and Zhenjun Luo. "A Human-Guided Vision-Based Measurement System for Multi-Station Robotic Motion Platform Based on V-Rep." Robotica 38, no. 7 (2019): 1227–41. http://dx.doi.org/10.1017/s0263574719001371.
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SUMMARYIn the manufacturing process of sophisticated and individualized large components, classical solutions to build large machine tools cannot meet the demand. A hybrid robot, which is made up of a 3 degree-of-freedom (3-DOF) parallel manipulator and a 2-DOF serial manipulator, has been developed as a plug-and-play robotized module that can be rapidly located in multi-stations where machining operations can be performed in situ. However, processing towards high absolute accuracy has become a huge challenge due to the movement of robot platform. In this paper, a human-guided vision system is proposed and integrated in the robot system to improve the accuracy of the end-effector of a robot. A handheld manipulator is utilized as a tool for human–robot interaction in the large-scale unstructured circumstances without intelligence. With 6-DOF, humans are able to manipulate the robot (end-effector) so as to guide the camera to see target markers mounted on the machining datum. Simulation is operated on the virtual control platform V-Rep, showing a high robust and real-time performance on mapping human manipulation to the end-effector of robot. And then, a vision-based pose estimation method on a target marker is proposed to define the position and orientation of machining datum, and a compensation method is applied to reduce pose errors on the entire machining trajectory. The algorithms are tested on V-Rep, and the results show that the absolute pose error reduces greatly with the proposed methods, and the system is immune to the motion deviation of the robot platform.
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Morales-Palma, D., Andrés Jesús Martinez-Donaire, Gabriel Centeno, M. Borrego, and Carpóforo Vallellano. "Teaching and Learning of Manufacturing Engineering through Virtualization of Processes on CNC Machines." Materials Science Forum 903 (August 2017): 112–19. http://dx.doi.org/10.4028/www.scientific.net/msf.903.112.
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This paper presents the latest developments in a digital documentation project related to manufacturing processes on machine tools. The project is supported by engineering students doing their bachelor/master thesis within this field. Different virtual models have been developed by using CATIA V5, such as conventional and CNC machines, several parts to be manufactured, and different manufacturing processes such as machining, incremental sheet forming and 3D printing. Some of the modelled parts have been manufactured. The developed digital documentation is used as supplementary material in subjects of bachelor and master degree in Industrial/Aerospace Engineering, with a high degree of acceptance by students.
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Shchurov, I. A., and I. S. Boldyrev. "FE-modeling of tapping for calculating the virtual pitch thread diamete." Bulletin of the South Ural State University series "Mechanical engineering industry" 23, no. 1 (2023): 73–80. http://dx.doi.org/10.14529/engin230107.
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The development of high-precision tapping operations involves predicting such accuracy. Very often, this requires expensive experiments. Numerical calculation methods, which have recently received wide application, make it possible to replace these experiments with computer simulations. However, this modeling is now mainly associated with determining the stresses and strength of tools, for which only the cutting tool itself and a fragment of the workpiece are modeled. This approach turns out to be unacceptable for predicting the machining accuracy, since the errors in the thread size and shape significantly depend on the actual movement of the tool, which, in turn, depends on the conditions of its fixing in the machine spindle. In this regard, the task concerns with not only the specified above technological system elements, but also an clamping tool. In addition, after calculating the thread surface of the part, it is necessary to calculate accuracy characteristics of this thread. It is these issues that are considered in this article: the results of finite element modeling of threading with a tap fixed in a tapping chuck of a floatingoscillating type are shown. The obtained graphs of axial force and torque correspond to the expected curves, both in its shape and in numerical values. The obtained thread point cloud made it possible to further calculate its virtual pith thread diameter, which turned out to be comparable with the corresponding tap diameter and the same thread size from the state standard. Thus, the above calculations show their realism and the possibility of application in the practice of designing thread-cutting operations.
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Takeuchi, Yoshimi. "Special Issue on Emerging Technology in Manufacturing." Journal of Robotics and Mechatronics 9, no. 6 (1997): 419. http://dx.doi.org/10.20965/jrm.1997.p0419.
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Manufacturing yields value from worthlessness. Thus, in recent years, manufacturing technologies have been undergoing rapid change in order to produce products of high quality, at a low cost and with short lead times. Improvements and innovations, with regard to manufacturing technologies, range from the fundamentals to large-scale systems. Therefore, the guest editor would like to introduce the new manufacturing technology, together with the latest research results. One of the most recent key technologies is the so-called rapid-prototyping technology. It shortens the development period of new products from the design stage. Many rapid-prototyping technologies are being developed concurrently. In this issue, the state of the art is explained clearly by an expert in the field. For mechanical products, manufacturing capabilities are highly dependent upon machine tools. In this issue, there is a research paper concerned with a design method for multi-purpose machine tools that can fabricate a variety of products. Machining efficiency is strongly influenced by the positioning accuracy and feed velocity of the axis movement of the machine tools. A control algorithm that can achieve high speed and accuracy is proposed in a paper in this issue. In order to make the most of NC machine tools, it is essential to provide NC data rapidly However, it is difficult to generate NC data, especially for multi-axis control machine tools capable of machining workpieces with complicated shapes. The development of 6-axis control CAM software for creating sculpted surfaces is reviewed in the issue. Another paper deals with NC data generation for sculpted surface processing using virtual reality. In FA systems, the nature of the programming/execution environment is shifting from a concentrated one to a distributed one, and a worker-friendly manufacturing environment is required for the workers. Two papers are presented for realizing such environments. Recently, ultra-precision machining and micro-machining technologies have been attracting great interest as a result of their ability to produce micro-mechanisms and micro-robots. One paper describes production of a prototypical tiny part with a sculpted surface using an ultra-precision milling machine. Another is related to simulation of an atomic level cutting mechanism that applies molecular dynamics. Manufacturing technology is making tremendous progress, and is putting promising new technologies into use toward the goal of realizing intelligent manufacturing systems, IMS. The guest editor heartily hopes that this issue aids in comprehension of the emerging technology in the manufacturing field.
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Weinert, Klaus, Sven Grünert, and Michael Kersting. "Analysis of Cutting Technologies for Lightweight Frame Components." Advanced Materials Research 10 (February 2006): 121–32. http://dx.doi.org/10.4028/www.scientific.net/amr.10.121.
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Most technical components applied in industrial practice are subjected to metal cutting operations during their production process. However, this leads to undesirable thermal and mechanical loads affecting the machined workpiece, which can result in an impairment of its serviceability. Due to their small wall thickness lightweight hollow profiles are highly susceptible to the inevitable machining loads and thermal stresses during drilling processes. For the virtual optimization of the machining process and in order to ensure a suitable process strategy, a finite element simulation of cutting operations for thin-walled light metal profiles is conducted. Due to the flexibility within creating drill holes of different diameters without tool changes circular milling represents a promising alternative to the application of conventional drilling tools for variable process strategies to handle batch sizes down to one piece efficiently. Hence, this article gives an insight into the investigations regarding the modeling concepts of the mechanical and thermal loads induced into the thin-walled lightweight frame structure during the circular milling process. Furthermore, process reliability aspects as well as the correlation of the calculated and the measured results will be discussed on the basis of experimental investigations. Finally, this article compares Finite Element Analysis aspects of circular milling processes with conventional drilling processes.
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Pezeshki, Mostafa, and Behrooz Arezoo. "Accuracy enhancement of kinematic error model of three-axis computer numerical control machine tools." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 231, no. 11 (2016): 2021–30. http://dx.doi.org/10.1177/0954405415619872.
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Accurate estimation of volumetric errors is an important issue in machining operations. For this purpose, a kinematic error model is used to characterize machine tool’s related errors on its workspace. In this research, it is shown that when measuring the linear and positioning errors using a laser interferometer, part of the angular errors are converted to linear and positioning errors and their magnitudes are overestimated. These values are calculated twice in the models which use homogeneous transformation matrix since Abbe’s principle is not considered. In this article, a kinematic error model is proposed which eliminates this overestimation. This model’s methodology is based on rigid body kinematic and errors measurement by laser interferometer and can be generalized for all three-axis machine tools. A software package is developed to integrate the kinematic errors with the NC-codes. A workpiece is machined in the virtual environment and compared with a workpiece machined in real environment. It is shown that the kinematic error model developed in this research predicts the kinematic errors more accurately.
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Rohrmoser, Andreas, Björn Heling, Benjamin Schleich, et al. "A Methodology for the Application of Virtual Evaluation Methods within the Design Process of Cold Forged Steel Pinions." Proceedings of the Design Society: International Conference on Engineering Design 1, no. 1 (2019): 3451–60. http://dx.doi.org/10.1017/dsi.2019.352.
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AbstractGears are essential machine elements in the drivetrain and transmission technology. The operational behaviour of a gear pairing is influenced by the design of the gear kinematics as well as the component properties. With regard to an improvement of performance and service life, the targeted modification of tooth geometry and component properties offers a promising approach. Thus, the achievable geometric and mechanical component properties are influenced by the manufacturing process, which must be taken into account in the design process. The application of virtual evaluation methods is suitable for this purpose. For the manufacturing of steel gears, cold forging provides the potential of achieving beneficial mechanical properties in a highly productive process. Major challenges for the industrial application are the short service life of the cost- intensive tools and the low geometric accuracy in comparison to machining processes. Within this study the design of the tooth geometry as well as the associated forming tool are investigated. The aim is to derive recommendations regarding an optimization of the resulting component properties and operational behaviour.
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Monková, Katarína, Peter Monka, Matej Somsak, and Andrej Andrej. "The Principles of Fixtures Design and their Application at Virtual Modelling in CAD/CAM System." Applied Mechanics and Materials 718 (December 2014): 99–104. http://dx.doi.org/10.4028/www.scientific.net/amm.718.99.
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The article deals with the principles of fixtures design and their application at virtual modelling in CAD/CAM system. The computers have became an important part of our life and about its benefits nobody doubts. The designers have got the strong tools into the development hands that use the potential of computer techniques for the creation of completely new applications, which alleviate the solution not only of common problems, but already the special defined, too. New technologies bring the change of mind. The classic way “production on the base of drawing” is often substituted by computer aid technology that thanks to three dimensional graphic enables to solve the difficult phases of the body design direct in its real version of full-value stereometric body. In the article are described the principles of the fixtures design using CAD/CAM system following by application of these rules for machining of complex shape armature.
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Kohn, Oliver, Julius Frenzel, Erkut Sarikaya, and Matthias Weigold. "Virtuelle Prozesssimulation einer CNC-Maschine/Virtual process simulation of a CNC machine – Digital twin for stress-based payment models." wt Werkstattstechnik online 113, no. 01-02 (2023): 24–28. http://dx.doi.org/10.37544/1436-4980-2023-01-02-28.
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Innovative Ansätze bei der Prozessplanung und -optimierung mittels digitaler Zwillinge erfordern leistungsfähige Simulationen für Werkzeugmaschinen. Die Entwicklung einer solchen Simulation für ein 3-Achs-Vertikal-Bearbeitungszentrum wird hier als hybride Multi-Domain-Simulation in „Modelica“ implementiert und experimentell validiert. Dabei ist das Ziel die berechneten Kenngrößen im Kontext aktueller Entwicklungen, wie zum Beispiel belastungsorientierter Bezahlmodelle bereitzustellen. Innovative approaches to process planning and optimization using digital twins require powerful simulations for machine tools. The development of such a simulation for a 3-axis vertical machining center is presented here. The hybrid multi-domain simulation is implemented in ‚Modelica‘ and validated experimentally. The aim is to provide the calculated parameters in the context of current developments such as load-oriented payment models.
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Shang, Suiyan, Gedong Jiang, Zheng Sun, et al. "Roughness prediction of end milling surface for behavior mapping of digital twined machine tools." Digital Twin 3 (March 29, 2023): 4. http://dx.doi.org/10.12688/digitaltwin.17819.1.
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Background: The quality of machined parts is considered as a relevant factor to evaluate the production performance of machine tools. For mapping the production performance into a digital twin machine tool, a virtual metrology model for surface roughness prediction, which affects products' mechanical capacity and aesthetic performance, is proposed in this paper. Methods: The proposed model applies a three-layer backpropagation neural network by using real-time vibration, force, and current sensor data collected during the end milling machining process. A grid search plan is used to settle down the number of neurons in the middle layer of the backpropagation neural network. Results: The experimental results indicate that the model with multiple signals as input performs better than it with a single signal. In detail, when the model input is the combination of force, vibration, and current sensor data, the prediction accuracy reaches the optimum with the mean absolute percentage error of 1.01%. Conclusions: Compared with the state-of-the-art convolutional neural network method with automatic feature extraction ability and other commonly used traditional machine learning methods, the proposed data preprocessing procedure integrated with a three-layer backpropagation neural network has a minimum prediction error.
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Xiu, Shijun, Jibo Li, Xiangjun Chen, Yifan Xia, and Pei Wang. "Study on the 2D Equivalent Simulation Model of Bearing and Spindle for Precision Machine Tools." Machines 11, no. 4 (2023): 461. http://dx.doi.org/10.3390/machines11040461.
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Precision spindle and bearings are the key components in precision machine tools. These structures greatly affect the machining accuracy and service life of the machine tools. In this paper, considering the uncertainty of rolling elements when the bearings are working at high speed, a new 2D equivalent simulation model of angular contact ball bearing was established based on the general finite element software, Abaqus. Meanwhile, the equivalent material parameters of virtual bearing ball in this 2D model were obtained via a standard bearing stiffness test and a parametric inversed method. The time to calculate of this model is reduced by 200 times compared with the 3D bearing simulation model. Then, the 2D equivalent simulation model of the spindle was established based on the 2D bearing model, which is used to calculate the axial stiffness and maximum contact stress between bearing balls and inner/outer rings in different assembly parameters. The results show that the stiffness of the spindle increases slowly at first, but then increases rapidly to a peak value after the bearing inner spacer sleeve is in contact with the bearing inner ring, and finally tends to stable, with the preload of the spindle continuing to increase.
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Samoylov, V. B. "Modernization of the System for Measuring Cutting Forces on the Basis of UDM Dynamometer Series." Herald of the Bauman Moscow State Technical University. Series Mechanical Engineering, no. 5 (128) (October 2019): 91–103. http://dx.doi.org/10.18698/0236-3941-2019-5-91-103.
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The purpose of the research was to analyze the existing systems for measuring forces during machining of parts on metal-cutting machine tools, and to consider the options for using both specialized ready-made solutions and dynamometer heads of the UDM series as measuring transducers. The study shows the drawbacks of the well-known general-circuit solutions for the modernization of these dynamometers, associated with the need to use heterogeneous sets of amplifying and transforming equipment. We propose low-budget solutions to improve the accuracy and reliability of measurements, to control and record measurement results in a modern software environment using virtual instruments. As a result of the study, we implemented hardware and software methods for processing measurement information, accompanying experimental studies in real time. The universal scalable systems developed for measuring moments and cutting forces are used both during academic research work and educational process of the university The work is carried out under the program "Scientific and scientific-pedagogical personnel of innovative Russia", event: 1.2.1. Scientific studies are done by research teams under the guidance of doctors of science; the research area is "Creation and processing of composite ceramic materials", the project is "Improving the efficiency of mechanical and abrasive machining of parts made of composite ceramic materials"
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Feng, Wei, Bin Yao, BinQiang Chen, DongSheng Zhang, XiangLei Zhang, and ZhiHuang Shen. "Modeling and Simulation of Process-Machine Interaction in Grinding of Cemented Carbide Indexable Inserts." Shock and Vibration 2015 (2015): 1–8. http://dx.doi.org/10.1155/2015/508181.
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Interaction of process and machine in grinding of hard and brittle materials such as cemented carbide may cause dynamic instability of the machining process resulting in machining errors and a decrease in productivity. Commonly, the process and machine tools were dealt with separately, which does not take into consideration the mutual interaction between the two subsystems and thus cannot represent the real cutting operations. This paper proposes a method of modeling and simulation to understand well the process-machine interaction in grinding process of cemented carbide indexable inserts. First, a virtual grinding wheel model is built by considering the random nature of abrasive grains and a kinematic-geometrical simulation is adopted to describe the grinding process. Then, a wheel-spindle model is simulated by means of the finite element method to represent the machine structure. The characteristic equation of the closed-loop dynamic grinding system is derived to provide a mathematic description of the process-machine interaction. Furthermore, a coupling simulation of grinding wheel-spindle deformations and grinding process force by combining both the process and machine model is developed to investigate the interaction between process and machine. This paper provides an integrated grinding model combining the machine and process models, which can be used to predict process-machine interactions in grinding process.
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BLECHA, PETR, JIRI MAREK, RADIM BLECHA, JANA ROZEHNALOVA, PETR HEINRICH, and PETR PACHER. "CNC MACHINE TOOL SAFETY FROM THE ASPECT OF HAZARD PERCEPTION BY OPERATING PERSONNEL." MM Science Journal 2022, no. 3 (2022): 5721–28. http://dx.doi.org/10.17973/mmsj.2022_10_2021123.
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Safety of machinery, including CNC machine tools, must be ensured in all phases of their life cycle. The operation and maintenance phase is the most important as it represents the longest period in the machine´s technical life linked to occurrence of work injuries. Every designer of a safe machine must consider also any reasonably foreseeable incorrect behaviour of the machine operator. The latest revision proposal of the Machinery Directive 2006/42/ES [EUR-LEX 2021] sets new requirements on solution of CNC machine tools safety. Aside from assessing the impact of cybersecurity on the machinery safety, the manufacturers will now have to take into account also the psychological stress arising from human-machine interaction. From the psychological point of view, the operating personnel of multifunctional CNC machine tools experience high level of stress when machining complicated and complex-shaped workpieces as the material often costs as much as 30% of the price of the machine; therefore, any mistake of the operator resulting in a nonconforming product causes high financial loss. Influence of various stressors on the operating personnel leads to their impaired concentration on the performed tasks, which may be accompanied by insufficient perception of the hazards associated with the machine operation and thus may lead to occurrence of work injuries. The presented paper discusses the factors that may put the operators of multifunctional CNC machine tools under psychological stress and analyses possible application of the virtual reality technology to assess the ability to perceive the hazards linked to such a complex machine on a group of university students representing both operators (beginners) and designers of a multifunctional CNC machine tool.