Implementing Rapid Prototyping Using CNC Machining (CNC-RP) Through a CAD/CAM Interface

This paper presents the methodology and implementation of a rapid machining system using a CAD/CAM interface. Rapid Prototyping using CNC Machining (CNC-RP) is a method that has been developed which enables automatic generation of process plans for a machined component. The challenge with CNC-RP is not the technical problems of material removal, but with all of the required setup, fixture and toolpath planning, which has previously required a skilled machinist. Through the use of advanced geometric algorithms, we have implemented an interface with a CAD/CAM system that allows true automatic NC code generation directly from a CAD model with no human interaction; a capability necessary for a practical rapid prototyping system.Mechanical Engineerin

Variation propagation of bench vises in multi-stage machining processes

Comunicación presentada a MESIC 2019 8th Manufacturing Engineering Society International Conference (Madrid, 19-21 de Junio de 2019)Variation propagation has been successfully modeled by the Stream of Variation (SoV) approach in multistage machining processes. However, the SoV model basically supports 3-2-1 fixtures based on punctual locators and other workholding systems such as conventional vises are not considered yet. In this paper, the SoV model is expanded to include the fixture- and datum-induced variations on workholding devices such as bench vises. The model derivation is validated through assembly and machining simulations on Computer Aided Design software. The case study analyzed shows an average error of part quality prediction between the SoV model and the CAD simulations of 0.26%

An Analytical Model for Repositioning of 6 D.O.F Fixturing System

Lien vers la version éditeur: http://journals.cambridge.org/action/displayAbstract?fromPage=online&aid=8749247&fulltextType=RA&fileId=S2257777712000164Dimensional errors of the parts from a part family cause the initial misplacement of the workpiece on the fixture affecting the final product quality. Even if the part is positioned correctly, the external machining forces and clamping load cause the part to deviate from its position. This deviation depends on the external load and the fixture stiffness. In this article, a comprehensive analytical model of a 3-2-1 fixturing system is proposed, consisting of a kinematic and a mechanical part. The kinematic model relocates the initially misplaced workpiece in the machine reference through the axial advancements of six locators taking all the fixturing elements to be rigid. The repositioned part then shifts again from the corrected position due to the deformation of fixturing elements under clamping and machining forces. The mechanical model calculates this displacement of the part considering the locators and clamps to be elastic. The rigid cuboid baseplate, used to precisely re-locate the workpiece, is also considered elastic at the interface with the locators. Using small displacement hypothesis with zero friction at the contact points, Lagrangian formulation enables us to calculate the rigid body displacement of the workpiece, deformation of each locator, as well as the stiffness matrix and mechanical behavior of the fixturing system. This displacement of the workpiece is then finally compensated by the advancement of the six axial locators calculated through the kinematic model

Zero-point fixture systems as a reconfiguration enabler in flexible manufacturing systems

ABSTRACT: Today's manufacturing systems need to be able to quickly adapt to customer demands, ranging from high volumes of mass production to high volumes of mass customization. Flexible Manufacturing Systems provide a high degree of flexibility to cope with these challenges. They consist of machine tools capable of executing a wide range of machining operations while the use of pallets to reference and block the parts allows the decoupling of the setup operations from the machining centers activity. This paper presents an ontology-based framework to support the design and management of flexible manufacturing systems, aimed at integrating the various involved activities including the pallet configuration and process planning, the management policies for short-term production planning and the pallet checking to verify the correct configuration of the physical pallet

Synchronization for different opinions in Malaysia Multiracial Society: a mathematical exploration study

Malaysia is known for the multiracial and multicultural society who lives together harmoniously despite of the diversities. The tolerance of the people towards each others’ culture and religions has always been the subject of interest for social science researchers. The harmony is due to the phenomena of synchronization of the notions among the community. Synchronization has been widely studied since it is a natural phenomena happening around us everyday, such as the synchronization of fireflies flashes at night. In relate of these, we anticipate in the study of the synchronization of the opinions in a diverse society with mathematical modelling. In this thesis, we analyse three different methods of synchronization by 3 different models: Kuramoto model, Opinion Changing Rate model and a linear model associate with the famous Friedkin and Johnsen Model. We first develop a modified version of existing mathematical models and then conduct the numerical experiment on the models to utilize them in the desired framework

A Survey of Automated Process Planning Approaches in Machining

Global industrial trend is shifting towards next industrial revolution Industry 4.0. It is becoming increasingly important for modern manufacturing industries to develop a Computer Integrated Manufacturing (CIM) system by integrating the various operational and information processing functions in design and manufacturing. In spite of being active in research for almost four decades, it is clear that new functionalities are needed to integrate and realize a completely optimal process planning which can be fully compliant towards Smart Factory. In order to develop a CIM system, Computer Aided Process Planning (CAPP) plays a key role and therefore it has been the focus of many researchers. In order to gain insight into the current state-of-the-art of CAPP methodologies, 96 research papers have been reviewed. Subsequent sections discuss the different CAPP approaches adopted by researchers to automate different process planning tasks. This paper aims at addressing the key approaches involved and future directions towards Smart Manufacturing

Computer aided process planning for multi-axis CNC machining using feature free polygonal CAD models

This dissertation provides new methods for the general area of Computer Aided Process Planning, often referred to as CAPP. It specifically focuses on 3 challenging problems in the area of multi-axis CNC machining process using feature free polygonal CAD models. The first research problem involves a new method for the rapid machining of Multi-Surface Parts. These types of parts typically have different requirements for each surface, for example, surface finish, accuracy, or functionality. The CAPP algorithms developed for this problem ensure the complete rapid machining of multi surface parts by providing better setup orientations to machine each surface. The second research problem is related to a new method for discrete multi-axis CNC machining of part models using feature free polygonal CAD models. This problem specifically considers a generic 3-axis CNC machining process for which CAPP algorithms are developed. These algorithms allow the rapid machining of a wide variety of parts with higher geometric accuracy by enabling access to visible surfaces through the choice of appropriate machine tool configurations (i.e. number of axes). The third research problem addresses challenges with geometric singularities that can occur when 2D slice models are used in process planning. The conversion from CAD to slice model results in the loss of model surface information, the consequence of which could be suboptimal or incorrect process planning. The algorithms developed here facilitate transfer of complete surface geometry information from CAD to slice models. The work of this dissertation will aid in developing the next generation of CAPP tools and result in lower cost and more accurately machined components

A concurrent approach to automated manufacturing process planning

textWith the increasing demand of fast-paced and hybrid manufacturing processes in modern industry, it is desirable to expedite the iterations between design and manufacturing through intelligent computational techniques. In this research, we propose a concurrent approach of this kind to streamline the design and manufacturing processes. With this approach, a CAD design is automatically analyzed in terms of its manufacturability in the early design stage. If the part is manufacturable, a set of process plans optimized in time, cost, fixture quality and tolerance satisfaction are reported in real time. If the part is not manufacturable, the potential design changes are provided for better manufacturing. In the approach, the geometric information of 3D models and the empirical knowledge in manufacturing processes, fixtures, and tolerances are combined and encapsulated into a graph-grammar based reasoning. The reasoning systematically extracts meaningful manufacturing details that later constitute complete process plans for any given solid model. The plans are then evaluated and optimized using a specially designed multi-objective best first search technique. The complete approach enables a concurrent and efficient manufacturability analysis tool that closely resembles real manufacturing planning practice. Numerous case studies with real engineering parts are presented to characterize the novelty and contributions of this approach. The optimality of the suggested plans is verified through computational comparisons, and the practicality of the plans is validated with hands-on implementations on the shop floor.Mechanical Engineerin

Experiments in fixturing mechanics

This paper describes an experimental fixturing system wherein fixel reaction forces, workpiece loading, and workpiece displacements are measured during simulated fixturing operations. The system's configuration, its measurement principles, and tests to characterize its performance are summarized. This system is used to experimentally determine the relationship between workpiece displacement and variations in fixed preload force or workpiece loading. We compare the results against standard theories, and conclude that commonly used linear spring models do not accurately predict workpiece displacements, while a non-linear compliance model provides better predictive behavior

Genetic algorithm optimization and robustness analysis for the computer aided design of fixture systems in automotive manufacturing

Fixture Systems (FSs) have great importance in machining, welding, assembly, measuring, testing and other manufacturing processes. One of the most critical issue in FS design is the choice of both the type of fixing devices such as clamps, locators, and support points, (configuration), and their arrangement with respect to workpieces (layout). Several authors deal with the problem of determine the most suitable solution for FSs, often investigating their layout without considering the change of the type of locators. A computer aided design method is proposed to compare and evaluate different configurations for a FS, optimizing the locator type and analysing the roboustness of the solution. A multi-objective optimization based on a genetic algorithm is presented and the selection of the most suitable configuration is performed through the definition of robustness indexes. The effectiveness of the design method is demonstrated for an automotive case study