Surface profile prediction and analysis applied to turning process

An approach for the prediction of surface profile in turning process using Radial Basis Function (RBF) neural networks is presented. The input parameters of the RBF networks are cutting speed, depth of cut and feed rate. The output parameters are Fast Fourier Transform (FFT) vector of surface profile for the prediction of surface profile. The RBF networks are trained with adaptive optimal training parameters related to cutting parameters and predict surface profile using the corresponding optimal network topology for each new cutting condition. A very good performance of surface profile prediction, in terms of agreement with experimental data, was achieved with high accuracy, low cost and high speed. It is found that the RBF networks have the advantage over Back Propagation (BP) neural networks. Furthermore, a new group of training and testing data were also used to analyse the influence of tool wear and chip formation on prediction accuracy using RBF neural networks

Path Coordination Planning and Control in Robotic Material Handling and Processing

This chapter presents a unified approach to coordination planning and control for robotic position and orientation trajectories in Cartesian space and its applications in robotic material handling and processing. The unified treatment of the end-effector positions and orientations is based on the robot pose ruled surface concept and used in trajectory interpolations. The focus of this chapter is on the determination and control of the instantaneous change laws of position and orientation, i.e., the generation and control of trajectories with good kinematics and dynamics performances along such trajectories. The coordination planning and control is implemented through controlling the motion laws of two end points of the orientation vector and calculating the coordinates of instantaneous corresponding points. The simulation and experiment in robotic surface profiling/finishing processes are presented to verify the feasibility of the proposed approach and demonstrate the capabilities of planning and control models. Keywords: Robot pose ruled surface, Unified approach, Trajectory planning and control, Off-line programming, Robotics polishin

Impact of disturbed drilling conditions on the surface integrity of a Nickel-base superalloy

Manufacturing critical parts for aerospace industry requires an important validation process to guarantee the quality of the produced components, and thus their fatigue life. Even with the best cutting conditions, disturbances can occur during the process and may have a direct impact on metallurgical quality. Through an experimental approach, this work presents the impact, during machining, of a lubricant interruption on the surface integrity and on the Process Monitoring signals. Finally a correlation between the thickness of the thermo-mechanically affected layer and the cutting power is made

Towards efficient 5-axis flank CNC machining of free-form surfaces via fitting envelopes of surfaces of revolution

We introduce a new method that approximates free-form surfaces by envelopes of one-parameter motions of surfaces of revolution. In the context of 5-axis computer numerically controlled (CNC) machining, we propose a flank machining methodology which is a preferable scallop-free scenario when the milling tool and the machined free-form surface meet tangentially along a smooth curve. We seek both an optimal shape of the milling tool as well as its optimal path in 3D space and propose an optimization based framework where these entities are the unknowns. We propose two initialization strategies where the first one requires a user’s intervention only by setting the initial position of the milling tool while the second one enables to prescribe a preferable tool-path. We present several examples showing that the proposed method recovers exact envelopes, including semi-envelopes and incomplete data, and for general free-form objects it detects envelope sub-patches

Edge finishing of large turbine casings using defined multi-edge and abrasive tools in automated cells

Automate finishing processes is a global challenge in several industrial sectors. Concretely, when dealing with aero-engine components, only simple finishing processes are automated nowadays. Most of the high-added value components manufactured are finished hand working, using deburring and polishing manual techniques. The driver of the proposed work is to achieve the necessary knowledge to introduce in a production line a complete finishing process for automated robotic deburring applications with low machinability materials (Inconel 718 in this case-study) on aero-engine casings with complex geometries: extruded casting bosses, internal features, etc. For this purpose, a three-step methodology is presented and analysed, providing a feasible workflow combining visual inspection for part positioning and edge location, with multi-edge solid tools and flexible abrasive tools to automate finishing operations, taking into account all process singularities. Results show that, using correct techniques, processes and parameters, an automated finishing process reducing operating time can be implemented in production lines.Thanks are addressed to the HAZITEK program from the Department of Economic Development and Infrastructures of the Basque Government and from FEDER founds, related to the project with acronym FAKTORIA. Authors are also grateful to the Basque government group IT IT1337-19. Finally, thanks are owed to the Ministry of Mineco REF DPI2016-74845-R and PID2019-109340RB-I00

New approach for robust multi-objective optimization of turning parameters using probabilistic genetic algorithm

In this paper, a contribution to the determination of reliable cutting parameters is presented, which is minimizing the expected machining cost and maximizing the expected production rate, with taking into account the uncertainties of uncontrollable factors. The concept of failure probability of stochastic production limitations is integrated into constrained and unconstrained formulations of multi-objective optimiza- tion problems. New probabilistic version of the nondominated sorting genetic algorithm P-NSGA-II, which incorporates the Monte Carlo simulations for accurate assessment of cumula- tive distribution functions, was developed and applied in two numerical examples based on similar and anterior work. In the first case, it is a question of the search space that is completely ‘ closed ’ by high natural variability related to the multi-pass roughing operation: in this case, the failure risk of technolog- ical limitations are considered as objectives to minimize with economic objectives. The second case is related to deformed search space due to the uncertainties specific to finishing op- eration; therefore, the economic objectives are minimized un- der imposed maximum probabilities of failure. In both situa- tions, the efficiency and robustness of optimal solution

Surface profile prediction and analysis applied to turning process

An approach for the prediction of surface profile in turning process using Radial Basis Function (RBF) neural networks is presented. The input parameters of the RBF networks are cutting speed, depth of cut and feed rate. The output parameters are Fast Fourier Transform (FFT) vector of surface profile for the prediction of surface profile. The RBF networks are trained with adaptive optimal training parameters related to cutting parameters and predict surface profile using the corresponding optimal network topology for each new cutting condition. A very good performance of surface profile prediction, in terms of agreement with experimental data, was achieved with high accuracy, low cost and high speed. It is found that the RBF networks have the advantage over Back Propagation (BP) neural networks. Furthermore, a new group of training and testing data were also used to analyse the influence of tool wear and chip formation on prediction accuracy using RBF neural networks

The use of stereolithography and related technologies to produce short run tooling

ThesisWhere material properties are critical to a polymer part, rapid prototype (RP) models are inappropriate for evaluation purposes and actual parts moulded in a range of materials are required for evaluation. Conventional tool making processes have extremely long lead times considering that numerous iterations may be required. The aim of this project was to generate polymer parts, utilising various approaches to Rapid Tooling (RT) , including Stereolithography or related technologies, as part of the process. The objective was to establish decision-making criteria for deciding on the appropriateness of various processes and the risks involved to assist prospective users of these technologies. The first phase of the project focused on the process validation of utilising Stereolithography as a direct means to generate injection mould tooling inserts, which were fitted into an injection mould designed for the trial purposes. The objective was to obtain process information with regard to insert generation for Stereolithography. A three dimensional model of the part was generated with CAD and the associated mould was generated around the part. The insert halves were processed and solid epoxy inserts were generated with the 3D Systems SLA500 Stereolithography machine. These inserts were post-finished and fitted to the injection mould . Additional features were added to the inserts to test cooling and gating and wear resistance of the cavity material. The author attended the basic injection tool setting course of the Plastics Federation to enable him to contribute more directly to this process. This also highlighted some of the design issues to facilitate ease of production . Initial difficulties were experienced in finding optimal process parameters. A total of 70 parts were produced, with measurable insert degradation. During the author's training at 3D Systems in the USA, he obtained additional insight in current methods of insert modelling and insert generation. If these process problems could be overcome, it would be possible to produce in excess of a 100 parts with one set of inserts, assuming a tolerance specification of 0.2mm. The cost of producing the inserts was approximately 50% that of conventional tooling fabrication . The time lapse between growing of the inserts and production of parts was one week compared to 6 to 8 weeks tool manufacture time with conventional methods. The second phase of the project focused on methods to enhance the cavity surface. Electroplating of inserts and inserts generated from Aluminium filled epoxy were tested , to investigate the effects that plating has on tool life, dimensional accuracy, temperature distribution, and the cost implications for these subsequent process steps. Stereolithography inserts were generated, taking into account the design considerations. Aluminium filled epoxy inserts were subsequently cast from silicone moulds drawn off the Stereolithography master patterns. Two sets of Stereolithography inserts were plated with 20 ~m of electrolytic nickel plating. One set of aluminium filled epoxy inserts were plated with electrolytic copper followed by electroless nickel. The mould sets were subjected to the same injection moulding trials using Polypropylene. The third phase of the project evaluated the use of Stereolithography investment casting masters to produce tool steel inserts, through the QuickCast process. Porosity was evident, with substantial machining required to fit the inserts. Not all the detail was retained during the casting process. Thin rib features on the part were thus lost. Due to the porosity the cooling was changed to copper tubes fitted into the rear of the tool and back-filled with aluminium epoxy. As the Stereolithography patterns were not polished the metal inserts had to be hand finished. This was a time consuming process and skill is required to obtain a good finish. A cost comparison indicated that machining aluminium inserts would be more cost effective. The tool manufacture time and eventual cost is not significantly less than conventional machining . In fact, trials with aluminium High speed CNC machining proved to be more time, finish and cost effective. This is discussed as part of the trial examples. Wax injection into AIM tooling was investigated on behalf of a client, with good results . As ceramic and polymer injection are very similar, apart from the ceramic being far more abrasive, it is the author's opinion that AIM tooling would be applicable, taking into account that fewer parts may be achieved. The KelTool process was also investigated during the author's USA visit. The licensing fees and additional equipment are extremely costly due to the Rand IDollar exchange rate. Issues related to this process are documented in this report. Clearly the deciding factors remain the quantity of parts required and the complexity of form. Each manufacturing process has a certain level of risk involved. Accumulative risk not only sets manufactured parts at risk but could jeopardise project time scales and iterations of a process have significant impact on a project budget

Bridge tooling through layered sintering of powder

Thesis (M. Tech.) - Central University of Technology, Free State, 2007Faster mould production methods will undeniably impact positively on the product development community. Rapid Tooling (RT) concepts, in context with the product development process and related product development theories, were analysed. Conventional tooling techniques used such as epoxy plastic tooling and machined injection moulding techniques were used as point of departure for the research work, which focused on Laser Sintering of powder materials. The new generation RT materials that are available at the Central University of Technology, Free State, are a vast improvement on the old materials. RT materials are constantly being developed and the project aims were to stay abreast with the latest developments. The thesis gives a complete overview of all related technologies, and also an in-depth discussion of both the Selective Laser Sintering (SLS) and Laser Sintering (LS) processes. Mould size limitations, as well as general tooling design issues, polishing and finishing techniques were all taken into account. Data has been collected to compare mould inserts grown with RP machines with that of conventionally machined tools. Aspects such as tool life, part quality, lead times and cost were used as parameters to determine the differences and make recommendations. Through analysis of several experiments and industrial case studies, RT through sintered materials was proven as a capable technology, giving the option of an intermediate (bridge tooling) or even a final step of tooling. Recommendations for future use were made in terms of insert size and geometry, accuracy, durability and shrinkages, to ensure the feasibility of the RT process in SA