Circular tests for HSM machine tools: Bore machining application

Today's High-Speed Machining (HSM) machine tool combines productivity and part quality. The difficulty inherent in HSM operations lies in understanding the impact of machine tool behaviour on machining time and part quality. Analysis of some of the relevant ISO standards (230-1998, 10791-1998) and a complementary protocol for better understanding HSM technology are presented in the first part of this paper. These ISO standards are devoted to the procedures implemented in order to study the behavior of machine tool. As these procedures do not integrate HSM technology, the need for HSM machine tool tests becomes critical to improving the trade-off between machining time and part quality. A new protocol for analysing the HSM technology impact during circular interpolation is presented in the second part of the paper. This protocol which allows evaluating kinematic machine tool behaviour during circular interpolation was designed from tests without machining. These tests are discussed and their results analysed in the paper. During the circular interpolation, axis capacities (such as acceleration or Jerk) related to certain setting parameters of the numerical control unit have a significant impact on the value of the feed rate. Consequently, a kinematic model for a circular-interpolated trajectory was developed on the basis of these parameters. Moreover, the link between part accuracy and kinematic machine tool behaviour was established. The kinematic model was ultimately validated on a bore machining simulation

A new conceptual approach for systematic error correction in CNC machine tools minimizing worst case prediction error

A new artifact-based method to identify the systematic errors in multi-axis CNC machine tools minimizing the worst case prediction error is presented. The closed loop volumetric error is identified by simultaneously moving the axes of the machine tool. The physical artifact is manufactured on the machine tool and later measured on a coordinate measuring machine. The artifact consists of a set of holes in the machine tool workspace at locations that minimize the worst case prediction error for a given bounded measurement error. The number of holes to be drilled depends on the degree of the polynomials used to model the systematic error and the number of axes of the machine tool. The prediction error is also function of the number and location of the holes. The feasibility of the method is first investigated for a two-axis machine to find the best experimental setting. Finally based on the two-axis case study, we extend the results to machine tools with any number of axes. The obtained results are very promising and require only a short time to produce the artifac

Novel robot arm design and implementation for hot forging press automation

Manual handling of hot and heavy workpiece in forging press industry increases the process time and causes safety risks to workers. To increase the productivity and optimise the use of manpower, manipulators are needed to be designed for supporting the workers handling the workpiece. Designing robots for such applications is challenging since the robot suffers from a heavy payload at the arm tip, and it operates at a high speed in a large workspace. This research addresses the design and implementation of a novel robot for handling workpiece for a given forging press cell. A novel robotic mechanism is designed with two key features: (i) the addition of parallel links in between serial links and (ii) the use of hydraulic actuators for driving robot’s joints. The addition of parallel links and the use of hydraulic cylinders are to increase the structural rigidity. It is also to reduce the number of joint variables and restrict the end-effector moving parallel to the ground surface so that the robot grips and releases the workpiece in a more efficient and simplified manner. The effectiveness of the designed robot mechanism is demonstrated through functional tests, and experimental results are carried out on the implemented robot

Life Cycle Assessment of Sugar from Sugarcane: A Case Study of Indonesia

Facing rising environmental concerns in the industry sector, especially sugar industry, requires to assess environmental performances. Minimizing the environmental impact like eco design is vital to save the earth. Life cycle assessment (LCA) is applied to know the impact of sugar production from agricultural stage to industrial stage, without considering their usage and disposal phases (cradle to gate). Eco Indicator 99 (H) is used as life cycle impact assessment (LCIA) methods in this study. Life cycle of sugar from sugar cane in Kebon Agung sugar company, East Java province, Indonesia is analyzed by SimaPro 7.3.3 software. Agricultural stage especially fertilizer usage is the largest source of emission in the whole sugar processing with dominant emissions in carcinogens and land use categories. It contributed 86% of whole impact. The contribution from de-ionsed water and burnt lime are also significant to give emission during industrial stage. It mainly affected respiratory inorganics impact category.

Real time inverse kinematics of a general 5-axis CNC machine

In most of the previous investigations, the kinematics model of five-axis computer-numerical control (CNC) centers was formulated just at the position level, and the differential kinematic relationships (velocity, acceleration and jerk of the five joints of a five-axis center) that are necessary for several purposes, especially for investigating the relationship between the limits of a machine’s drives and the feed rate maximization (the productivity maximization), have been overlooked. Therefore, this paper addresses the differential kinematic modelling and analysis for the five-axis CNC centers. In particular, the differential kinematic equations are formulated in a parametric domain so that they are useful for investigating the kinematic behaviors of the five-axis centers in real time

A New Optimal Selection Method with Seasonal Flow and Irrigation Variability for Hydro Turbine Type and Size

A micro hydropower plant of the run-of-river type is considered to be the most cost-effective investment in developing counties. This paper presents a novel methodology to improve flow estimation, without using the flow direction curve (FDC) method, to determine the turbine type and size to operate consistently. A higher precision is obtained through the use of seasonal flow occurrence data, irrigation variability, and fitting the best probability distribution function (PDF) using flow data. Flow data are grouped in classes based on the flow rate range. This method will need a larger dataset but it is reduced to a tractable amount by using the PDF. In the first part of the algorithm, the average flow of each range is used to select the turbine type. The second part of the algorithm determines the optimal size of the turbine type in a more accurate way, based on minimum and maximum flow rates in each class range instead of the average flow rate. A newly developed micro hydropower plant was installed and used for validation at Baan Khun Pae, Chiang Mai Province. It was found, over four years of observation from 2014⁻2018, that the plant capacity factor was 82%

Knowledge-based approach for stretch blow molding

The general principle of stretch blow molding is easy to describe but in practice it requires considerable knowledge and skill. Currently people apply their own knowledge gained through a blend of experience, intuition, and guesswork. As a result, there could be different solutions proposals for the same problem. Furthermore, it is not unusual to propose different solution at different times for the same problem. The stretch blow molding process, like other manufacturing processes, appears to be an appropriate domain for knowledge-based system (KBS) development. A KBS was developed to aid the designer for the selection of resin, design of preform and container, and processing. The KBS contains about 200 production rules. A guided forward chaining concept is used for inferencing. The user needs to input the basic requirements such as volume of the container, end use, etc for a systematic advice