Measurement and compensation of pivot point positional error on five-axis machines

Measuring and compensating the pivot points of five-axis machine tools is always challenging and very time consuming. This paper presents a newly developed approach for automatic measurement and compensation of pivot point positional errors on five-axis machine tools. Machine rotary axis errors are measured using a circular test. This method has been tested on five-axis machine tools with swivel table configuration. Results show that up to 99% of the positional errors of the rotary axis can be compensated by using this approach.

Guest editorial:special issue on digitial enterprise technology

Full text This Proceedings volume contains selected papers from the Fourth International CIRP-sponsored, Conference on Digital Enterprise Technology (DET2007), which was held at the University of Bath, UK, 19–21 September 2007. All selected papers have been suitably enhanced for publication in the Journal and have undergone full review. Digital enterprise technology (DET) is ‘the collection of systems and methods for the digital modelling and analysis of the global product development and realization process, in the context of lifecycle management.’ The principal aim of the DET concept is to provide a coherent context for the development and integration of the various digital technologies that underpin modern design and manufacturing. These technologies can be classified according to the following five key areas. 1. Distributed and collaborative design. 2. Process modelling and process planning. 3. Advanced factory design and modelling. 4. Physical-to-digital environment integrators–verification. 5. Enterprise integration technologies. This special issue is representative of the wide breadth of the DET concept including; a comprehensive review of digital engineering, design processes, digital modelling of machine tools, forming, robotics and machining processes, verification and metrology, and dynamic networks. It is particularly pleasing to see the development of metrology as a key aspect of modern manufacturing technology, linking design intent to process capability. The papers published herein will facilitate the exploration of new and evolving research concepts by the international research community and will influence the development of international standards for the application of DET technologies.

Design and analysis of a 2-DoF split-stator induction motor

A two degrees of freedom (2-DOF) actuator capable of producing linear translation, rotary motion, or helical motion would be a desirable asset to the fields of machine tools, robotics, and various apparatuses. In this paper, a novel 2-DOF split-stator induction motor was proposed and electromagnetic structure pa- rameters of the motor were designed and optimized. The feature of the direct-drive 2-DOF induction motor lies in its solid mover ar- rangement. In order to study the complex distribution of the eddy current field on the ferromagnetic cylinder mover and the motor’s operating characteristics, the mathematical model of the proposed motor was established, and characteristics of the motor were ana- lyzed by adopting the permeation depth method (PDM) and finite element method (FEM). The analytical and numerical results from motor simulation clearly show a correlation between the PDM and FEM models. This may be considered as a fair justification for the proposed machine and design tools.

Development of an open architecture motion control system

A multipurpose open architecture motion control system was developed with three platforms for control and monitoring. The Visual Basic user interface communicated with the operator and gave instructions to the electronic components. The first platform had a BASIC Stamp based controller and three stepping motors. The second platform had a controller, amplifiers and two DC servomotors. The third platform had a DSP module. In this study, each platform was used on machine tools either to move the table or to evaluate the incoming signal. The study indicated that by using advanced microcontrollers, which use high-level languages, motor controllers, DSPs (Digital Signal Processor) and microcomputers, the motion control of different systems could be realized in a short time. Although, the proposed systems had some limitations, their jobs were performed effectively. ^

Otimização dos parâmetros de maquinagem no processo de fresagem

Cada vez mais, os principais objetivos na indústria é a produção a baixo custo, com a máxima qualidade e com o tempo de fabrico o mais curto possível. Para atingir esta meta, a indústria recorre, frequentemente, às máquinas de comando numérico (CNC), uma vez que com esta tecnologia torna se capaz alcançar uma elevada precisão e um tempo de processamento mais baixo. As máquinas ferramentas CNC podem ser aplicadas em diferentes processos de maquinagem, tais como: torneamento, fresagem, furação, entre outros. De todos estes processos, o mais utilizado é a fresagem devido à sua versatilidade. Utiliza-se normalmente este processo para maquinar materiais metálicos como é o caso do aço e dos ferros fundidos. Neste trabalho, são analisados os efeitos da variação de quatro parâmetros no processo de fresagem (velocidade de corte, velocidade de avanço, penetração radial e penetração axial), individualmente e a interação entre alguns deles, na variação da rugosidade num aço endurecido (aço 12738). Para essa análise são utilizados dois métodos de otimização: o método de Taguchi e o método das superfícies. O primeiro método foi utilizado para diminuir o número de combinações possíveis e, consequentemente, o número de ensaios a realizar é denominado por método de Taguchi. O método das superfícies ou método das superfícies de resposta (RSM) foi utilizado com o intuito de comparar os resultados obtidos com o método de Taguchi, de acordo com alguns trabalhos referidos na bibliografia especializada, o RSM converge mais rapidamente para um valor ótimo. O método de Taguchi é muito conhecido no setor industrial onde é utilizado para o controlo de qualidade. Apresenta conceitos interessantes, tais como robustez e perda de qualidade, sendo bastante útil para identificar variações do sistema de produção, durante o processo industrial, quantificando a variação e permitindo eliminar os fatores indesejáveis. Com este método foi vi construída uma matriz ortogonal L16 e para cada parâmetro foram definidos dois níveis diferentes e realizados dezasseis ensaios. Após cada ensaio, faz-se a medição superficial da rugosidade da peça. Com base nos resultados obtidos das medições da rugosidade é feito um tratamento estatístico dos dados através da análise de variância (Anova) a fim de determinar a influência de cada um dos parâmetros na rugosidade superficial. Verificou-se que a rugosidade mínima medida foi de 1,05m. Neste estudo foi também determinada a contribuição de cada um dos parâmetros de maquinagem e a sua interação. A análise dos valores de “F-ratio” (Anova) revela que os fatores mais importantes são a profundidade de corte radial e da interação entre profundidade de corte radial e profundidade de corte axial para minimizar a rugosidade da superfície. Estes têm contribuições de cerca de 30% e 24%, respetivamente. Numa segunda etapa este mesmo estudo foi realizado pelo método das superfícies, a fim de comparar os resultados por estes dois métodos e verificar qual o melhor método de otimização para minimizar a rugosidade. A metodologia das superfícies de resposta é baseada num conjunto de técnicas matemáticas e estatísticas úteis para modelar e analisar problemas em que a resposta de interesse é influenciada por diversas variáveis e cujo objetivo é otimizar essa resposta. Para este método apenas foram realizados cinco ensaios, ao contrário de Taguchi, uma vez que apenas em cinco ensaios consegue-se valores de rugosidade mais baixos do que a média da rugosidade no método de Taguchi. O valor mais baixo por este método foi de 1,03μm. Assim, conclui-se que RSM é um método de otimização mais adequado do que Taguchi para os ensaios realizados. Foram obtidos melhores resultados num menor número de ensaios, o que implica menos desgaste da ferramenta, menor tempo de processamento e uma redução significativa do material utilizado.

EGCL: an extended G-Code Language with flow control, functions and mnemonic variables

In the context of computer numerical control (CNC) and computer aided manufacturing (CAM), the capabilities of programming languages such as symbolic and intuitive programming, program portability and geometrical portfolio have special importance -- They allow to save time and to avoid errors during part programming and permit code re-usage -- Our updated literature review indicates that the current state of art presents voids in parametric programming, program portability and programming flexibility -- In response to this situation, this article presents a compiler implementation for EGCL (Extended G-code Language), a new, enriched CNC programming language which allows the use of descriptive variable names, geometrical functions and flow-control statements (if-then-else, while) -- Our compiler produces low-level generic, elementary ISO-compliant Gcode, thus allowing for flexibility in the choice of the executing CNC machine and in portability -- Our results show that readable variable names and flow control statements allow a simplified and intuitive part programming and permit re-usage of the programs -- Future work includes allowing the programmer to define own functions in terms of EGCL, in contrast to the current status of having them as library built-in functions

Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

The milling of thin parts is a high added value operation where the machinist has to face the chatter problem. The study of the stability of these operations is a complex task due to the changing modal parameters as the part loses mass during the machining and the complex shape of the tools that are used. The present work proposes a methodology for chatter avoidance in the milling of flexible thin floors with a bull-nose end mill. First, a stability model for the milling of compliant systems in the tool axis direction with bull-nose end mills is presented. The contribution is the averaging method used to be able to use a linear model to predict the stability of the operation. Then, the procedure for the calculation of stability diagrams for the milling of thin floors is presented. The method is based on the estimation of the modal parameters of the part and the corresponding stability lobes during the machining. As in thin floor milling the depth of cut is already defined by the floor thickness previous to milling, the use of stability diagrams that relate the tool position along the tool-path with the spindle speed is proposed. Hence, the sequence of spindle speeds that the tool must have during the milling can be selected. Finally, this methodology has been validated by means of experimental tests.

Fault diagnostics and supervised testing : How fault diagnostic tools can be proactive?

The topic of fault detection and diagnostics (FDD) is studied from the perspective of proactive testing. Unlike most research focus in the diagnosis area in which system outputs are analyzed for diagnosis purposes, in this paper the focus is on the other side of the problem: manipulating system inputs for better diagnosis reasoning. In other words, the question of how diagnostic mechanisms can direct system inputs for better diagnosis analysis is addressed here. It is shown how the problem can be formulated as decision making problem coupled with a Bayesian Network based diagnostic mechanism. The developed mechanism is applied to the problem of supervised testing in HVAC systems.

A. An investigation of the relation between the tensile strength and (Brinell) hardness of non-ferrous alloys. B. A design of a fatigue testing machine for a college laboratory

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