A Virtual Machining Model for Sustainability Analysis

2010 ◽  
Author(s):  
Guodong Shao ◽  
Deogratias Kibira ◽  
Kevin Lyons
Keyword(s):  
Environmental Impact ◽  
Social Performance ◽  
Sustainable Manufacturing ◽  
Simulation Models ◽  
Numerical Control ◽  
Machining Process ◽  
Shop Floor ◽  
Sustainable Machining ◽  
Virtual Machining ◽  
Machining System

Sustainability has become a very significant research topic since it impacts many different manufacturing industries. The adoption of sustainable manufacturing practices and technologies offers industry a cost effective route to improve economic, environmental, and social performance. As a major manufacturing process, the machining system plays an important role for sustainable manufacturing on the factory floor. Therefore, technologies for monitoring, analyzing, evaluating, and optimizing the sustainability impact of machining systems are critical for decision makers. Modeling and Simulation (M&S) can be an effective tool for success of sustainable manufacturing through its ability to predict the effect of implementing a new facility, process without interrupting real production. This paper introduces a methodology that provides a traditional virtual Numerical Control (NC) machining model with a new capability — to quantitatively analyze the environmental impact of machining system based on Life Cycle Assessment (LCA). The objective of the methodology is to analyze the sustainability impacts of machining process and determine a better plan for improving the sustainable performance of machining system in a virtual environment before work orders are released to the shop floor. Testing different scenarios with simulation models ensures the best setting option available can be chosen. The virtual NC model provides the necessary data for this assessment. In this paper, a list of environmental impact indicators and their metrics has been identified, and modeling elements for sustainable machining have been discussed. Inputs and outputs of the virtual machining model for sustainable machining are described. A case study to experiment the proposed methodology is discussed.

Synchronous Adjustment of Milling Tool Path Based on the Relative Deviation

2011 ◽  
Vol 133 (5) ◽  
Author(s):  
Xiao-Jin Wan ◽  
Cai-Hua Xiong ◽  
Lin Hua
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
Cnc Machining ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Accuracy ◽  
Source File ◽  
Modern Computer ◽  
Adjustment Strategy ◽  
Machining System

In machining process, machining accuracy of part mainly depends on the position and orientation of the cutting tool with respect to the workpiece which is influenced by errors of machine tools and cutter-workpiece-fixture system. A systematic modeling method is presented to integrate the two types of error sources into the deviation of the cutting tool relative to the workpiece which determines the accuracy of the machining system. For the purpose of minimizing the machining error, an adjustment strategy of tool path is proposed on the basis of the generation principle of the cutter location source file (CLSF) in modern computer aided manufacturing (CAM) system by means of the prediction deviation, namely, the deviation of the cutting tool relative to the workpiece in computer numerical control (CNC) machining operation. The resulting errors are introduced as adjustment values to adjust the nominal tool path points from cutter location source file from commercial CAM system prior to machining. Finally, this paper demonstrates the effectiveness of the prediction model and the adjustment technique by two study cases.

scholarly journals Development of smart machining system for optimizing feedrates to minimize machining time

2017 ◽  
Vol 5 (3) ◽  
pp. 299-304 ◽  
Author(s):  
Hong-seok Park ◽  
Bowen Qi ◽  
Duck-Viet Dang ◽  
Dae Yu Park
Keyword(s):  
Cutting Force ◽  
Machining Process ◽  
Cnc Machine ◽  
Machining Time ◽  
Virtual Machining ◽  
Milling Operations ◽  
Nc Program ◽  
Machining System ◽  
Optimal Feed ◽  
Smart Machining

Abstract Feedrate optimization is an important aspect of getting shorter machining time and increase the potential of efficient machining. This paper presents an autonomous machining system and optimization strategies to predict and improve the performance of milling operations. The machining process was simulated and analyzed in virtual machining framework to extract cutter-workpiece engagement conditions. Cutting force along the cutting segmentation is evaluated based on the laws of mechanics of milling. In simulation, constraint-based optimization scheme was used to maximize the cutting force by calculating acceptable feedrate levels as the optimizing strategy. The intelligent algorithm was integrated into autonomous machining system to modify NC program to accommodate these new feedrates values. The experiment using optimized NC file which generates by our smart machining system were conducted. The result showed autonomous machining system, was effectively reduced 26%. Highlights The smart machining system was implemented in the CNC machine. Optimal feed rates enhance machine tool efficiency. The smart machining system is reliable to reduce machine time.

Research on Technologies of Augmented Reality for CNC Machining Process Simulation

2013 ◽  
Vol 579-580 ◽  
pp. 276-282 ◽  
Author(s):  
Zhi Yan Ma ◽  
Guang You Yang ◽  
Xu Wu Su
Keyword(s):  
Process Simulation ◽  
Physical Simulation ◽  
Removal Rate ◽  
Cnc Machining ◽  
Numerical Control ◽  
Machining Process ◽  
Numerical Control Machining ◽  
Machining Process Simulation ◽  
Machining System ◽  
Real Machine

Based on Virtual Numerical Control machining system (VNC), a new method of Augmented Numerical Control machining system (ANC) which aims at the realization of NC machining process simulation in real machining environment is put forward. The System inputs continuous video images of real NC processing environment through camera to identify and locate the major machining and positioning parts of real machine in the image stream. And the virtual parts of VNC will be matched to the corresponding real ones of real machining system to achieve the registration of ANC. The NC system drives the virtual machining models for processing through a real machine. On the other hand, the actual running information of CNC machine are imported into the ANC system to drive some models of process variables such as cutting force, material removal rate, chip shape, tool temperature, cutting tool wear. ANC provides the platform to integrate the geometry and physical simulation based on actual information from real CNC machining environment.

scholarly journals Surface Roughness Prediction and Minimization in 5-Axis Milling Operations of Gas Turbine Blades

2021 ◽  
Author(s):  
Arameh Eyvazian ◽  
Farayi Musharavati ◽  
Afrasyab Khan ◽  
Mohsen Soori ◽  
Tamer A. Sebaey ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Gas Turbine ◽  
Turbine Blades ◽  
Machining Process ◽  
Machining Parameters ◽  
Gas Turbine Blades ◽  
Virtual Machining ◽  
Machined Parts ◽  
Machining System

Abstract To enhance the quality of machined parts, virtual machining systems are presented in this study. In the turbine blades, the minimization of the surface roughness of the blades can decrease the Reynolds number to decrease the loss of energy in power generation. Due to difficulties of polishing process in minimizing the surface roughness of machined blades, the optimized machining parameters for minimizing the surface roughness is an effective solution for the problem. In this study, a virtual machining system is developed to predict and minimize the surface roughness in 5-Axis machining operations of gas turbine blades. To minimize the surface roughness, the machining parameters were optimized by the Genetic algorithm. To validate the developed system, the turbine blades were machined using a 5-Axis CNC machine tool and the machined blades were measured using the CMM machine to obtain the surface roughness of machined parts. So, a 41.29% reduction in the measured surface roughness and a 42.09% reduction in the predicted surface roughness are obtained using the optimized machining parameters. The developed virtual machining system can be applied in the machining process of turbine blades to enhance the surface quality of machined blades and thus improve the efficiency of gas turbines.

Tool Deflection Error of Three-Axis Computer Numerical Control Milling Machines, Monitoring and Minimizing by a Virtual Machining System

2016 ◽  
Vol 138 (8) ◽  
Author(s):  
Mohsen Soori ◽  
Behrooz Arezoo ◽  
Mohsen Habibi
Keyword(s):  
Manufacturing Systems ◽  
Optimization Technique ◽  
Dimensional Accuracy ◽  
Virtual Manufacturing ◽  
Numerical Control ◽  
Free Form ◽  
Machining Parameters ◽  
Tool Deflection ◽  
Virtual Machining ◽  
Machining System

Virtual manufacturing systems carry out the simulation of manufacturing processes in digital environment in order to increase accuracy as well as productivity in part production. There are different error sources in machine tools, such as tool deflection, geometrical deviations of moving axis, and thermal distortions of machine tool structures. The errors due to tool deflection are caused by cutting forces and have direct effects on dimensional accuracy, surface roughness of the parts, and efficient life of the cutting tool, holder, and spindle. This paper presents an application of virtual machining systems in order to improve the accuracy and productivity of part manufacturing by monitoring and minimizing the tool deflection error. The tool deflection error along machining paths is monitored to present a useful methodology in controlling the produced parts with regard to desired tolerances. Suitable tool and spindle can also be selected due to the ability of error monitoring. In order to minimize the error, optimization technique based on genetic algorithms is used to determine optimized machining parameters. Free-form profile of virtual and real machined parts with tool deflection error is compared in order to validate reliability as well as accuracy of the software.

Research about Numerical Control Machining of STL Files Based on Fagor CNC System

2011 ◽  
Vol 314-316 ◽  
pp. 1597-1602 ◽  
Author(s):  
Chao Wang ◽  
Yuan Yao ◽  
Qian Sheng Zhao ◽  
Qing Xi Hu
Keyword(s):  
Numerical Control ◽  
Machining Process ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc System ◽  
Numerical Control Machining ◽  
Nc Code ◽  
Virtual Machining ◽  
Cnc Milling Machine ◽  
System Designs

According to the situation that surface grid models are widely used, this article summarizes the research status of numerical control machining based on Triangle facets models, introduces the STL files in detail, expounds the process of machining STL files by using Pro/Toolmaker system, designs an independent post processor for generating NC code for Fagor machine, simulates the virtual machining process through Vericut software, verifies the actual machining process on Fagor three axis CNC milling machine. Proves the method of numerical control machining based on STL files is actually feasible for planar milling、cavity milling、profile milling, Realizes the machining of STL files based on Fagor CNC system.

Modeling of Virtual Machining System for Contour Milling of Gear Indexing Cam

2006 ◽  
Vol 532-533 ◽  
pp. 793-796
Author(s):  
Pei Quan Guo ◽  
Chuan Zhen Huang ◽  
Jin Ping Shi ◽  
Xiao Xia Li
Keyword(s):  
Dynamic Response ◽  
Dynamic Analysis ◽  
Dynamic Models ◽  
Geometrical Model ◽  
Machining Process ◽  
Product Model ◽  
Virtual Machining ◽  
Machining System ◽  
Cutting Zone ◽  
Plate Dynamic

Geometrical model of virtual machining system was introduced. Based on the analysis of the machining system, it was divided into workpiece subsystem and tool subsystem. Dynamic models of subsystems have been established by means of simplification of machining system. Dynamic analysis and simulation have been done. Model of virtual machining system is the combination of geometrical model and dynamic model. Based on the dynamic analysis and simulation of virtual machining system, conclusion was drawn: (1) In cutting process, as cutter feeds into cutting zone, vibration appears and becomes stronger and stronger. As cutter tends to leave cutting zone, vibration becomes weaker and weaker and disappears finally. The most violent vibration occurs as cutter has engaged into cutting zone and as cutter tends to leave cutting zone. (2) As machining corresponding to dwell of indexing plate, dynamic response is smooth and steady. (3) Vibration will attenuate sharply after cutter leaving cutting zone. The operation of virtual machining system accords with the appearance in real machining process. Properties of product model are very close to those of real machined cam.

scholarly journals A Novel Method of Sustainability Evaluation in Machining Processes

Processes ◽  
2019 ◽  
Vol 7 (5) ◽  
pp. 275 ◽  
Author(s):  
Haiming Sun ◽  
Conghu Liu ◽  
Jianqing Chen ◽  
Mengdi Gao ◽  
Xuehong Shen
Keyword(s):  
Conversion Efficiency ◽  
Manufacturing Industry ◽  
Energy Resource ◽  
Machining Process ◽  
Utilization Rate ◽  
Sustainability Evaluation ◽  
Machining Processes ◽  
Sustainable Machining ◽  
Machining System ◽  
Improvement Method

In order to quantitatively evaluate and improve the sustainability of machining systems, this paper presents an emergy (the amount of energy consumed in direct and indirect transformations to make a product or service) based sustainability evaluation and improvement method for machining systems, contributing to the improvement of energy efficiency, resource efficiency and environmental performance, and realizing the sustainability development. First, the driver and challenge are studied, and the scope and hypothesis of the sustainable machining system are illustrated. Then, the emergy-based conversion efficiency model is proposed, which are (1) effective emergy utilization rate (EEUR), (2) emergy efficiency of unit product (EEUP) and (3) emergy conversion efficiency (ECE), to measure and evaluate the sustainable machining system from the perspectives of energy, resource and environment. Finally, the proposed model is applied to a vehicle-bridge machining process, and the results show that this paper provides the theoretical and method support for evaluating and improving the sustainable machining processes to decouple the resources and development of the manufacturing industry.

Towards Smart and Competitive Sustainable Machining

2010 ◽  
Vol 447-448 ◽  
pp. 301-305
Author(s):  
Pei Ling Liu
Keyword(s):  
Simulation Analysis ◽  
Model Simulation ◽  
Sustainable Manufacturing ◽  
Cutting Speed ◽  
Cnc Machining ◽  
Raw Material ◽  
Machining Process ◽  
Sustainable Machining ◽  
Cnc Programming ◽  
Machining Productivity

Computer Numeric Control (CNC) revolutionized the machining technology and has been the cutting edge of digital manufacturing since 1950s. CNC machining model, simulation, verification, and optimization have been a vivid research topic of Smart Machining that automated the CNC programming (CAM) and cutting process, hence greatly increased machining productivity since 1990s. This paper traces back the history of CNC simulation, analysis the different CNC machining models, tested with application examples, and listed different CNC verification industry applications for the last 20 years. The new challenge comes from sustainable manufacturing. Towards smart and competitive sustainable machining, CNC model and simulation will be used to optimize the machining process, where the raw material could be saved through First Part Correct technology, the energy could be saved through cutting speed optimization, and used parts could be saved by remanufacturing.

Minimum Quantity Lubrication (MQL) Using Ranque – Hilsch Vortex Tube (RHVT) for Sustainable Machining

2012 ◽  
Vol 217-219 ◽  
pp. 2012-2015 ◽  
Author(s):  
Ha Salaam ◽  
Zahari Taha ◽  
Tuan Muhammad Yusoff Shah Tuan Ya
Keyword(s):  
Environmental Impact ◽  
Vortex Tube ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Effective Solution ◽  
Sustainable Machining ◽  
Minimum Quantity ◽  
Thermal Test ◽  
Mixture Separation ◽  
Ice Production

Ranque-Hilsch Vortex Tube (RHVT) is a device with no moving parts and do not require electricity or chemicals to function. It has been used widely in cooling and heating of various operations, thermal test, dehumidification, gas liquefaction, ice production and mixture separation. Sustainable machining refers to the efforts to reduce the environmental impact of machining. The use of minimum quantity lubrication (MQL) is an effective solution for a more sustainable machining process. In this paper we propose the use of RHVT in MQL. The structure, working principles and types of RHVT are presented in this paper. Parameters associated with RHVT and the various possible working fluids are discussed in brief.

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