In this paper an efficient geometry description algorithm is proposed that reads the cutting-edge points of an arbitrary broaching tool from the provided model in a pixelated format which is surely available in any engineering environment. The created geometry can be scaled arbitrarily and used for simulations, ensuring adaptability due to its point cloud like format. High precision machining requires l (…)
This paper presents a machine learning based tool for the automated analysis of circuit diagrams, identifying electrical consumers through computer vision. Detected technical information is extracted and summarized in a report. In a web-based interactive dashboard the identified consumers are prioritized for further actions. Based on their nominal power an ABC-analysis classifies the consumers into thre (…)
High speed machines such as laser cutting machines should realize movements with high accelerations. Dynamical limitations of the feed drives are typically related to the bandwidth of the control loops and the excitation of mechanical structure. The objective of this article is to analyze the effect of feedforward control techniques on the individual axes tracking performance. Feed drive simulation mode (…)
The structural vibration caused by poor rigidity is one of the main obstacles limiting the machining efficiency of robot milling. The existing vibration suppression strategies mainly focus on process parameter optimization, passive vibration absorption at the end and feedback control of joint motor. Although these strategies have certain vibration suppression effects, they cannot directly improve the st (…)
Drilling is a crucial process in industrial production and the quality of the machined hole has a decisive impact on the final part quality. However, there are various disturbances in the manufacturing process, which makes the non-value-adding quality inspection unavoidable. In this paper, high-frequently recorded internal NC-signal data and the vibration sensor data from the machine protection control (…)
Manufacturing operations in large machine tools often requires several hours per part. Ensuring output quality is vital to avoid time and financial losses. While quality assurance was always problematic and costly, the recent advent of Industry 4.0 brought a new perspective to the problem as cutting machines are now fully digitized. This paper proposes a process control framework that combines a fingerp (…)
For many applications, the surface quality, geometric accuracy and stress state of parts produced using laser-based powder bed fusion (PBF-LB) are insufficient. A stress relief and machining as post-processing operations allow to overcome these issues. PBF-LB materials have a unique microstructure. Their machinability therefore differs from that of cast or wrought materials. The microstructure can be al (…)
This article analyses the influence of tool orientation on the geometry and surface finish obtained during the machining of thin-walled curved freeform surface parts on multitasking machining centre. These complex surfaces parts have direct application in blade manufacturing for the aeronautical sector, which has very high quality standards and are difficult to achieve. In addition, the material used is (…)
Non-traditional machining methods like wire electric discharge machining (WEDM) appear to be an ideal choice for machining high strength super alloys like Inconel 706, because of their capability to generate intricate profiles with high accuracy. However, wire breakages are a common problem in the WEDM process and adversely affect the productivity, accuracy, and surface quality. Therefore, the aim of th (…)
Accuracy is one of the most important feature of a machine tool. Being able to estimate the overall accuracy of a machine tool represented by the total volumetric error can be a huge advantage in the design process. This paper provides overview of methods used for geometric error transfer modeling and volumetric error modeling. An error transfer rigid body model is derived and after that, a random linea (…)
In many facets of industry, slender workpieces are formed by means of milling processes. These workpieces are especially prone to experience harmful chatter vibrations, which limits quality and productivity. In this paper, a novel solution is proposed where a robotic arm is used to support the workpiece, improving its modal properties and reducing the occurrence of chatter. The paper presents some numer (…)
The development of part quality virtual sensors requires knowledge and observability of cutting conditions and in particular tool wear as tool are consumables. This paper presents an unsupervised anomalies detection approach to assess tool wear from standard machine load sensors in order to evaluate a non-quality risk metric. The developed methodology combines physics and business rules with density est (…)
In this paper, different approaches to visualize CAM simulation results are presented. Simulated machined surfaces can be rendered in a photorealistic manner taking into account real tool motions and vibrations measured during the machining process. The actual tool trajectories are used to derive the microrelief of machined surface that lead to different reflective properties to be used in the CAM surfa (…)
Tool wear, caused by high machining temperatures, cutting speed or mechanical load, can have various characteristics. Current solutions for metrological quantification are limited with respect to their viewing dependency and user influence. Here, a measurement solution which is based on 3D focus variation measurements is presented. The quantification is carried out by the automatic evaluation of flank w (…)
Multilateration-based volumetric error mapping is gaining widespread adoption in the coordinate measurement machine and machine tool industry as the most effective approach for geometric characterization of large-size machines. In the traditional method, tracking interferometers are placed on the machine table while the measurement retro-reflector moves with the spindle. However, this approach has sever (…)
This study investigates the influence of different texturing inclinations on the cutting forces and surface roughness during hard turning with ceramic cutting tools of X100CrMoV8 cold work tool steel. Four linear textures with inclinations ranging from 0° to 45° were tested. The results show that textured tools exhibited similar cutting forces to the reference tool, with a slight increase using a 30° in (…)
Monocrystalline silicon has anisotropic attributes due to asymmetric and non-uniform interatomic lattice structures, which affects its deformation and fracture properties. This paper aims to investigate the effect of crystallographic orientation on the material deformation and removal behavior during high speed scratching of monocrystalline silicon. A high-speed scratching setup is developed which can a (…)
High-speed ultrasonic vibration cutting shown great advantages by cutting temperature reduction due to periodic opened cutting interfaces for direct heat convection with coolants. To figure out accurate heat transfer ability, a 2-dimensional simplified model was developed and computational fluid dynamics (CFD) was used to calculate heat flux and Nusselt number. Three flank wear lengths for initial, init (…)
Industrial robots are more compliant than CNC machine tools, which makes them prone to chatter during robotic milling. Chatter has slowed down the adoption or sometimes inhibited the use of robots for machining tasks. This work presents a new chatter suppression scheme by mounting a magnetorheological fluid (MRF) absorber on the spindle housing to absorb the vibration with a specific frequency range. Fi (…)
The productivity of machining processes is often limited by the occurrence of dynamic effects. The investigated approach intends to counteract tool deflections, and thus to damp and disrupt chatter vibrations by using milling tools with defined functional structures on the flank faces at the frontal cutting edges. For the fundamental investigation of the interactions between structural geometric propert (…)
Temperature analysis in the manufacturing phase of the product is necessary for improving the operational performance of the workpiece. In screw whirling milling, the analysis of cutting temperature is different from turning or milling due to the complicated contact characteristics between the tool, workpiece and chip. In this study, a temperature model is developed for predicting the temperature distri (…)
Additive Manufacturing techniques represent a revolution for the design of certain engineering components traditionally subject to a design highly influenced by the manufacturing process linked to the manufacture of the component. Additive Manufacturing techniques therefore allow components with different internal and external structures to be manufactured. Thus, components formed by an internal microst (…)
As a member of the latest generation of powder metallurgy Ni-based superalloy, FGH96 has already been widely applied in the manufacturing of aero-engines because of its distinguished mechanical performances. The surface integrity plays an essential role in the final fatigue life of the machined parts. However, surface modification induced by the machining process is inevitable, which profoundly affects (…)
In the industrial field, the search for improving the performance of machining tools considering their geometry, manufacturing, material, and coatings is a priority. This research focuses on optimizing the cutting edge for broaching Inconel 718. Drag-finishing was used to round and polish the cutting edge of a K10-Co 7% grade tungsten carbide roughing tool. The results reveal that increasing the cutting (…)
Impact test is a universal method to characterize the fatigue property of coated tools. For the bilayer TiSiN/TiAlN coated tool, the stress state in the cutting process with different feed rates were explored through cutting experiments. A high-temperature and high-frequency impact test platform was built. Through the impact tests with the introduction of the ‘pre-loading depth’, the fatigue properties (…)
Chatter is a common state in the end milling, which has major influence on machining quality. Early chatter detection is a prerequisite for taking adequate measures to avoid chatter. Nevertheless, there are still numerous challenges and difficulties in the feature extraction of chatter detection. In this paper, effective chatter detection in the milling process of a vibration signal is investigated usin (…)
Low-frequency chatter severely limits robotic milling efficiency. In this paper, tuned mass dampers (TMDs) are introduced to suppress low-frequency chatter based on robotic modal directionality. A TMD model with mounting angle is established, and the suppression effect of TMD on the robotic low-frequency dynamic compliance with different mounting directions is analyzed together with experiments. Then, l (…)
The cutter-workpiece engagement (CWE) is an important basis for accurately predicting milling force and vibration of machining system, which can be dramatically affected by the complex tool path, variable part allowance and various tool profiles. The paper presents a fast calculation method of CWE during peripheral milling process based on the Boolean operation. A second-developed simulation environment (…)
This industrial article focuses on the finishing machining of workpieces made of aluminium alloy EN AW 7075 with a freeform shape, utilizing minimal material stocks. These workpieces are widely used in sectors like aviation and the energy industry. In these sectors, there is a pressing demand for high-quality production in the initial attempt, eliminating the need for subsequent post-processing operatio (…)
This research article aims to investigate the impact of various types of powder coatings on the resulting dimensional accuracy in the optical 3D scanning process. The experimental study utilises the GOM ATOS II Triple Scan scanner with measuring volume MV100 to conduct a series of measurements. Different powder coatings, varying in composition and application area, are sequentially applied to the measur (…)
The design of semiconductor-metallic nanostructures using pulsed laser ablation in liquids (PLAL) is a very demanding task for biomedical applications being at an early stage of its development. Only few recent papers show the possibility of such a synthesis of composite nanoparticles as well as their perspectives for biosensing applications. However, mechanisms of the laser-stimulated formation of semi (…)
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