Intelligent dual curve-driven tool path optimization and virtual CMM inspection for sculptured surface CNC machining

This paper investigates the profitability of a dual‐curve driven surface finish tool path under the concept of optimizing crucial machining parameters such as toroidal end‐mill diameter, lead angle and tilt angle. Surface machining error as well as tool path time are treated as optimization objectives under a multi‐criteria sense, whilst a central composite design is conducted to obtain experimental outputs for examination and, finally, fit a full quadratic model considered as the fitness function for process optimization by means of a genetic algorithm. A benchmark sculptured surface given as a second‐order parametric equation was tested and simulated using a cutting‐edge manufacturing modeling software and best parameters recommended by the genetic algorithm were implemented for validation. Further assessment involves the virtual inspection to selected profile sections on the part. It was shown that the approach can produce dual‐curve driven tool trajectories capable of eliminating sharp scallop heights, maximizing machining strip widths as well as maintaining smoothness quality and machining efficiency

Influence of the ratio on the mechanical properties of epoxy resin composite with diapers waste as fillers for partition panel application

Materials play significant role in the domestic economy and defense with the fast growth of science and technology field. New materials are the core of fresh technologies and the three pillars of modern science and technology are materials science, power technology and data science. The prior properties of the partition panel by using recycled diapers waste depend on the origin of waste deposits and its chemical constituents. This study presents the influence of the ratio on the mechanical properties of polymer in diapers waste reinforced with binder matrix for partition panel application. The aim of this study was to investigate the influence of different ratio of diapers waste polymer reinforced epoxy-matrix with regards to mechanical properties and morphology analysis. The polymer includes polypropylene, polystyrene, polyethylene and superabsorbent polymer (SAP) were used as reinforcing material. The tensile and bending resistance for ratio of 0.4 diapers waste polymers indicated the optimum ratio for fabricating the partition panel. Samples with 0.4 ratios of diapers waste polymers have highest stiffness of elasticity reading with 76.06 MPa. A correlation between the micro structural analysis using scanning electron microscope (SEM) and the mechanical properties of the material has been discussed

Process planning for the rapid machining of custom bone implants

This thesis proposes a new process planning methodology for rapid machining of bone implants with customized surface characteristics. Bone implants are used in patients to replace voids in the fractured bones created during accident or trauma. Use of bone implants allow better fracture healing in the patients and restore the original bone strength. The manufacturing process used for creating bone implants in this thesis is highly automated CNC-RP invented at Rapid Manufacturing and Prototyping Lab (RMPL) at Iowa State University. CNC-RP is a 4th axis rapid machining process where the part is machined using cylindrical stock fixed between two opposing chucks. In addition to conventional 3 axes, the chucks provide 4th rotary axis that allows automated fixturing setups for machining the part. The process planning steps for CNC-RP therefore includes calculating minimum number of setup orientations required to create the part about the rotary axis. The algorithms developed in this thesis work towards calculating a minimum number of orientations required to create bone implant with their respective surface characteristics. Usually bone implants may have up to 3 types of surfaces (articular/periosteal/fractured) with (high/medium/low) finish. Currently CNC-RP is capable of creating accurate bone implants from different clinically relevant materials with same surface finish on all of the implant surfaces. However in order to enhance the functionality of the bone implants in the biological environment, it is usually advisable to create implant surfaces with their respective characteristics. This can be achieved by using setup orientations that would generally isolate implant surfaces and machine them with individual finishes. This thesis therefore focuses on developing process planning algorithms for calculating minimum number of orientations required to create customized implant surfaces and control related issues. The bone implants created using new customization algorithms would have enhanced functionality. This would reduce the fracture healing time for the patient and restore the original bone strength. The software package created using new algorithms will be termed as CNC-RPbio throughout in this thesis The three main tasks in this thesis are a) calculating setup orientations in a specific sequence for implant surfaces b) Algorithms for calculating a minimum number of setup orientations to create implant surfaces c) Machining operation sequence. These three research tasks are explained in details in chapter 4 of this thesis. The layout of this thesis is as follows. Chapter 1 provides introduction, background and motivation to the research in this thesis. Chapter 2 provides a literature review explaining different researches conducted to study the effects of different surface finish on the bone implants on their functionality. It also presents different non-traditional and RP techniques used to create bone implant geometries with customized surfaces, their advantages and limitations. Chapter 3 gives the overview of process planning algorithms used for CNC-RP and those needed for CNC-RPbio. Chapter 4 is the main chapter of the thesis including process planning algorithms for rapid machining of bone implants with customized surfaces using CNC-RP in details, while Chapter 5 provides Conclusions and Future work

Performance Analysis of An Experimental Micro Flexible Manufacturing System (FMS)

Due to advanced technology, it is very important the performance of FMS for sensivity, production quality, repeatability and energy consumptions. Flexible manufacturing systems (FMSs) are the most automated and technologically sophisticated of the machine cell types used to implement cellular manufacturing. An FMS usually has multiple automated stations and is capable of variable routings among stations, while its flexibility allows it to operate as a mixed model system. The FMS concept integrates many of the advanced technologies that we met in previous units, including flexible automation, CNC machines, distributed computer control, and automated material handling and storage. In this experimental investigation, vibration and accelerations analysis of an experimental FMS with 5 degrees of freedom robot manipulator are presented. Firstly, experimental measurement of accelerations and vibrations are trained with a vibration measurement system and sensors. However, the process of production of part is a cycle of exact production time

New cognitive info-communication channels for human-machine interaction

The main goal of this paper is to discuss a new paradigm for robot teaching and supervising which is based on cognitive info-communication channels for human-machine interaction. According to the studied concept the robot is considered as an unskilled worker “who” (which) is strong and capable for precise manufacturing. “He” (it) has a special kind of intelligence, but “he” is handicapped in some senses, that is why “he” needs special treatment. We must command “him” clearly in a special way and we must supervise “his” work. If we can elaborate a proper way for communicating with this “new worker”, as an additional dimension of robotization, we can get a capable new “colleague”. The ultimate goal is to help the boss to be able to give the daily task to a robot in a similar way as he/she able to give the jobs to the human workers. For example, by providing the CAD documentation with some additional verbal explanation