Vision-assisted robotic finishing of friction stir-welded corner joints

One required process in the fabrication of large components is welding, after which there may be a need for machining to achieve final dimensions and uniform surfaces. Friction stir-welding (FSW) is a typical example after which a series of deburring and grinding operations are carried out. Currently, the majority of these operations are carried out either manually, by human workers, or on machine tools which results in bottlenecks in the process flows. This paper presents a robotic finishing system to automate the finishing of friction stir-welded parts with minimum human involvement. In a sequence, the system can scan and reconstruct the 3D model of the part, localise it in the robot frame and generate a suitable machining path accordingly, to remove the excess material from FSW without violating process constraints. Results of the cutting trials carried out for demonstration have shown that the developed system can consistently machine the corner joints of an industrial scale part to desired surface quality which is around 1.25 μm in, Ra, the arithmetic average of the surface roughness

Laser beam characterisation for industrial applications

This thesis describes the theory, development and applications of laser beam characterisation for industrial laser materials processing systems. Descriptions are given of novel forms of beam diagnostic systems and their integration into highly automated industrial tools. Work is also presented that has contributed to the new ISO standard on beam characterisation. Particular emphasis is given to excimer laser applications and UV micromachining. [Continues.

Quality and inspection of machining operations: Review of condition monitoring and CMM inspection techniques 2000 to present

In order to consistently produce quality parts, many aspects of the manufacturing process must be carefully monitored, controlled, and measured. The methods and techniques by which to accomplish these tasks has been the focus of numerous studies in recent years. With the rapid advances in computing technology, the complexity and overhead that can be feasibly incorporated in any developed technique has dramatically improved. Thus, techniques that would have been impractical for implementation just a few years ago can now be realistically applied. This rapid growth has resulted in a wealth of new capabilities for improving part and process quality and reliability. In this paper, overviews of recent advances that apply to machining are presented. Moreover, due to the relative significance of two particular machining aspects, this review focuses specifically on research publications pertaining to using tool condition monitoring and coordinate measurement machines to improve the machining process. Tool condition has a direct effect on part quality and is discussed first. The application of tool condition monitoring as it applies to turning, drilling, milling, and grinding is presented. The subsequent section provides recommendations for future research opportunities. The ensuing section focuses on the use of coordinate measuring machines in conjunction with machining and is subdivided with respect to integration with machining tools, inspection planning and efficiency, advanced controller feedback, machine error compensation, and on-line tool calibration, in that specific order and concludes with recommendations regarding where future needs remain

The future of Cybersecurity in Italy: Strategic focus area

This volume has been created as a continuation of the previous one, with the aim of outlining a set of focus areas and actions that the Italian Nation research community considers essential. The book touches many aspects of cyber security, ranging from the definition of the infrastructure and controls needed to organize cyberdefence to the actions and technologies to be developed to be better protected, from the identification of the main technologies to be defended to the proposal of a set of horizontal actions for training, awareness raising, and risk management

Monitoring of hybrid manufacturing using acoustic emission sensor

The approach of hybrid manufacturing addressed in this research uses two manufacturing processes, one process builds a metal part using laser metal deposition, and the other process finishes the part using a milling machining. The ability to produce complete functioning parts in a short time with minimal cost and energy consumption has made hybrid manufacturing popular in many industries for parts repair and rapid prototyping. Monitoring of hybrid manufacturing processes has become popular because it increases the quality and accuracy of the parts produced and reduces both costs and production time. The goal of this work is to monitor the entire hybrid manufacturing process. During the laser metal deposition, the acoustic emission sensor will monitor the defect formation. The acoustic emission sensor will monitor the depth of cut during milling machining. There are three tasks in this study. The first task addresses depth-of-cut detection and tool-workpiece engagement using an acoustic emission monitoring system during milling machining for a deposited material. The second task, defects monitoring system was proposed to detect and classify defects in real time using an acoustic emission (AE) sensor and an unsupervised pattern recognition analysis (K-means clustering) in conjunction with a principal component analysis (PCA). In the third task, a study was conducted to investigate the ability of AE to detect and identify defects during laser metal deposition using a Logistic Regression Model (LR) and an Artificial Neural Network (ANN) --Abstract, page iv

Towards a flexible future ? The nature of organisational response in the clothing industry.

In this contribution, the central questions concern the need for structural transformation, the diffusion of innovative organisational practices, and the dominance of particular organisational models in the Belgian clothing industry. In order to answer these questions, the results of two Trend Study surveys are used, covering a total of 104 companies : a 1995 survey among companies employing more than 50 workers and a 1996 survey in the segment of companies employing between 20 and 50 workers.Industry;

Investigation of the electrical and mechanical requirements for the automation of a process in flexible material manufacture

This thesis describes a successful attempt to automate a manual process in footwear industry. The process is called skiving of leather components and it is one of the early processes necessary for the assembly of shoe uppers. Skiving is the localised thinning of leather components, mainly at some of their edge regions. The purpose of skiving is to produce quality decorative edges or more importantly to enable attaching and joining components without forming thick, discomforting and weak joints. Although other processes in footwear manufacturing have been subject to partial or full automation, skiving has been performed for decades now with a standard mechanism that requires 3-dimensional manipulation of the components by a human operator. This research work was directed towards two main aims. One was to establish a novel method on the basis of which skiving may be performed without the need of human assistance. The developed method is called dynamic matrix skiving and it is capable of performing skiving on leather components by generating and actuating skive patterns as sets of finite elements of skived area to a given resolution. Following derivation and study of the method for skiving, the second phase was aimed at implementing a fully automatic skiving system. The main requirement from the system was to be an intelligent, component oriented, flow through, processing device. This required the capability to receive input components at any orientation and position along its transport mechanism, to recognise them as to their identity and relative position, and to perform skiving upon them without moving them or disturb their continuous flow throughout the entire operation. Individual chapters in this thesis describe the study and experimentation with regards to dynamic matrix skiving, and all logical steps taken to identify the necessary elements and implement their integration to produce the automated skiving system. The concluding part of this work includes presentation of the results obtained from the automated system, and it identifies the areas where further research and development is needed in order to improve the quality of its output

Reliability Analysis of On-Demand High-Speed Machining

Current trends in high-speed machining aim to increase manufacturing efficiency by maximizing material removal rates and minimizing part cycle times. This project explores three related technologies and presents a system design for rapid production of custom machined parts. First a reliability analysis in high-speed machining of thin wall features is put forth with experimental results. Second an implementation of on-demand manufacturing is presented with emphasis on flexibility and automation. Finally innovative manufacturing cell design is used to drive costs down by optimizing material and information flow. The resulting high-speed on-demand machining cell design employs effective techniques to reduce production time, meet changing customer needs, and drive down costs