Online on-board optimization of cutting parameter for energy efficient CNC milling

Energy efficiency is one of the main drivers for achieving sustainable manufacturing. Advances in machine tool design have reduced the energy consumption of such equipment, but still machine tools remain one of the most energy demanding equipment in a workshop. This study presents a novel approach aimed to improve the energy efficiency of machine tools through the online optimization of cutting conditions. The study is based on an industrial CNC controller with smart algorithms optimizing the cutting parameters to reduce the overall machining time while at the same time minimizing the peak energy consumption

Therblig-embedded value stream mapping method for lean energy machining

To improve energy efficiency, extensive studies have focused on the cutting parameters optimization in the machining process. Actually, non-cutting activities (NCA) occur frequently during machining and this is a promising way to save energy through optimizing NCA without changing the cutting parameters. However, it is difficult for the existing methods to accurately determine and reduce the energy wastes (EW) in NCA. To fill this gap, a novel Therblig-embedded Value Stream Mapping (TVSM) method is proposed to improve the energy transparency and clearly show and reduce the EW in NCA. The Future-State-Map (FSM) of TVSM can be built by minimizing non-cutting activities and Therbligs. By implementing the FSM, time and energy efficiencies can be improved without decreasing the machining quality, which is consistent with the goal of lean energy machining. The method is validated by a machining case study, the results show that the total energy is reduced by 7.65%, and the time efficiency of the value-added activities is improved by 8.12% , and the energy efficiency of value-added activities and Therbligs are raised by 4.95% and 1.58%, respectively. This approach can be applied to reduce the EW of NCA, to support designers to design high energy efficiency machining processes during process planning

Intelligent systems in manufacturing: current developments and future prospects

Global competition and rapidly changing customer requirements are demanding increasing changes in manufacturing environments. Enterprises are required to constantly redesign their products and continuously reconfigure their manufacturing systems. Traditional approaches to manufacturing systems do not fully satisfy this new situation. Many authors have proposed that artificial intelligence will bring the flexibility and efficiency needed by manufacturing systems. This paper is a review of artificial intelligence techniques used in manufacturing systems. The paper first defines the components of a simplified intelligent manufacturing systems (IMS), the different Artificial Intelligence (AI) techniques to be considered and then shows how these AI techniques are used for the components of IMS

Optimization of machining processes using pattern search algorithm

Optimization of machining processes not only increases machining efficiency and economics, but also the end product quality. In recent years, among the traditional optimization methods, stochastic direct search optimization methods such as meta-heuristic algorithms are being increasingly applied for solving machining optimization problems. Their ability to deal with complex, multi-dimensional and ill-behaved optimization problems made them the preferred optimization tool by most researchers and practitioners. This paper introduces the use of pattern search (PS) algorithm, as a deterministic direct search optimization method, for solving machining optimization problems. To analyze the applicability and performance of the PS algorithm, six case studies of machining optimization problems, both single and multi-objective, were considered. The PS algorithm was employed to determine optimal combinations of machining parameters for different machining processes such as abrasive waterjet machining, turning, turn-milling, drilling, electrical discharge machining and wire electrical discharge machining. In each case study the optimization solutions obtained by the PS algorithm were compared with the optimization solutions that had been determined by past researchers using meta-heuristic algorithms. Analysis of obtained optimization results indicates that the PS algorithm is very applicable for solving machining optimization problems showing good competitive potential against stochastic direct search methods such as meta-heuristic algorithms. Specific features and merits of the PS algorithm were also discussed

The relevance of outsourcing and leagile strategies in performance optimization of an integrated process planning and scheduling

Over the past few years growing global competition has forced the manufacturing industries to upgrade their old production strategies with the modern day approaches. As a result, recent interest has been developed towards finding an appropriate policy that could enable them to compete with others, and facilitate them to emerge as a market winner. Keeping in mind the abovementioned facts, in this paper the authors have proposed an integrated process planning and scheduling model inheriting the salient features of outsourcing, and leagile principles to compete in the existing market scenario. The paper also proposes a model based on leagile principles, where the integrated planning management has been practiced. In the present work a scheduling problem has been considered and overall minimization of makespan has been aimed. The paper shows the relevance of both the strategies in performance enhancement of the industries, in terms of their reduced makespan. The authors have also proposed a new hybrid Enhanced Swift Converging Simulated Annealing (ESCSA) algorithm, to solve the complex real-time scheduling problems. The proposed algorithm inherits the prominent features of the Genetic Algorithm (GA), Simulated Annealing (SA), and the Fuzzy Logic Controller (FLC). The ESCSA algorithm reduces the makespan significantly in less computational time and number of iterations. The efficacy of the proposed algorithm has been shown by comparing the results with GA, SA, Tabu, and hybrid Tabu-SA optimization methods

Multi-Objective Optimization in Machining (Turning) of Copper

A multi-objective optimization problem has been showcased in this work, which involves the use of both the TOPSIS and Utility in the case study in machining of copper. The machining process turning is being studied with the aim of identifying the best possible environmental parameters, so that the present day need of quality and productivity can be satisfied simultaneously. The conventional Taguchi method has the drawback of failing to solve multi-objective optimization cases. Hence we use TOPSIS and Utility model to get rid of this constraint. These two, when coupled with concept of Taguchi creates a single response optimization environment from a multi-response optimization case. The closeness and Utility Index are the governing single objective function that assist the optimization process. This merger of Taguchi concept with TOPSIS/Utility process gives the best]/optimal setting. The data from closeness coefficient and utility index are in turn used to find the S/N ratio based on Taguchi concept. The process environment corresponding to maximum value of S/N ratio of closeness coefficient and utility index is considered as the optimum solution. The verification has been made by other conformity test. The above study gives us an insight for feasible application of the above methodology as multi-response optimization of copper machining process and its off-line control are being studied to improve the productivity as well as the qualit