Integration of CAD/tool path data for 5-axis STEP-NC machining of free form/irrregular controured surfaces.

This research paper presents the work on feature recognition, tool path data generation and integration with STEP-NC (AP-238 format) for features having Free form/Irregular Contoured Surfaces(s) (FICS). Initially, the FICS features are modelled/imported in UG CAD package and a closeness index is generated. This is done by comparing the FICS features with basic B-Spines/Bezier curves/surfaces. Then blending functions are caculated by adopting convolution theorem. Based on the blending functions, contour offsett tool paths are generated and simulated for 5 axis milling environment. Finally, the tool path (CL) data is integrated with STEP-NC (AP-238) format. The tool path algorithm and STEP-NC data is tested with various industrial parts through an automated UFUNC plugin

An IoT based industry 4.0 architecture for integration of design and manufacturing systems.

This paper proposes an Internet of Things (IoT) based 5-stage Industry 4.0 architecture to integrate the design and manufacturing systems in a Cyber Physical Environment (CPE). It considers the transfer of design and manufacturing systems data through the Cloud/Web-based (CW) services and discusses an effective way to integrate them. In the 1st stage, a Radio-Frequency IDentification (RFID) technology containing Computer Aided Design (CAD) data/models of the product with the ability to design / redesign is scanned and sent to a secure Internet/Cloud Server (CS). Here the CAD models are auto identified and displayed in the Graphical User Interface (GUI) developed for the purpose. From the scanned RFID CAD data/models, the 2nd stage adopts unique machine learning technique(s) and identifies the design & manufacturing features information required for product manufacture. Once identified, the 3rd stage handles the necessary modelling changes as required to manufacture the part by verifying the suitability of process-based product design through user input from the GUI. Then, it performs a Computer Aided Process Planning (CAPP) sequence in a secure design cloud server designed using web-based scripting language. After this, the 4th stage generates Computer Aided Manufacturing (CAM) toolpaths by continuous data retrieval of design and tooling database in the web server by updating the RFID technology with all the information. The various processes involved the 3rd and 4th stages are completed by using ‘Agents’ (a smart program) which uses various search and find algorithms with the ability to handle the changes to the process plan as required. Finally, the 5th stage, approves the product manufacture instructions by completing the production plan with the approved sheets sent to the Computer Numerical Control (CNC) machine. In this article, the proposed architecture is explained through the concept of IoT data transfer to help industries driving towards Industry 4.0 by improving productivity, reducing lead time, protecting security and by maintaining internationals standards / regulations applied in their workplace

A FEA simulation study of ball end mill for fixed 3+1 / 3+2 axis machining of Ti-6Al-4V.

This paper presents a Finite Element Analysis (FEA) simulation study conducted on ball endmill for fixed 3 + 1 and 3 + 2 axis orientations for machining Ti-6Al-4 V. This work adopts a tungsten carbide (WC) ∅18.6 mm diametrical/6fluted ball endmill to analyse maximum principal elastic strain (ϵmax-max-principal-elastic), maximum principal stress (σmax-principal)along with cutting tools forces in the axial (Fz), radial (Fy), tangential (Fx) and total (Ftotal) directions. The machining orientations considered for 3 + 1 and 3 + 2 axis are (i) tilt angles of 5°, 10°, 15° & 20° and (ii) lead angles of 5°, 10° & 15° with a constant fixed tilt angle of 10°. The cutting speed and feed rate per tooth is taken as 450 m/min and 0.5 mm/tooth. These are based on a high speed machining (HSM) scenario and has been dynamically simulated for a maximum of 175,000 cycles. From the simulation study considered at 16-20 valid cutting points, it can be noticed that in 3 + 1 axis, for a tilt angle of 10° and 3 + 2 axis for a Tilt 10°/Lead 10° the σmax-principaland ϵmax-max-principal-elasticare higher when compared with all tilt/lead angles. In case of total forces (Ftotal) from all 3 directions (Fx, Fyand Fz) not much variation can be noticed for different tilt/lead angles, but higher values are recorded with 3 + 1 axis at 5° tilt angle and 3 + 2 axis at tilt/lead angle of 10°. The paper provides a critical comparative study on the 3 + 1/ 3 + 2 axis orientations highlighting the cutting strain/stress with tool forces at valid cutting points considering entry, middle and exit region of the blank by emphasizing the importance of cutting tool design parameters

A digital twin study for immediate design / redesign of impellers and blades: part 1: CAD modelling and tool path simulation.

This paper presents a digital twining study conducted for an immediate design / redesign and manufacturing of on impellers and blades. It is by accomplished by developing (i) CAD automation methods, based on the standard modelling procedures and (ii) Manufacturing automation based on the 3/3 + 1/3 + 2/5 axis milling process. Initially, the CAD model of impeller / blade is created by utilizing the dimensional parameters obtained through standard design calculations / data. It is then parametrized and converted to an automated model through simple dimensional rules and geometric algorithms developed for the purpose. After this stage, the CAD model is analyzed for manufacturing automation where the process planning data comprising cutting tools, process parameters and setups are selected. Here, the tool paths are generated for 3/3 + 1/3 + 2/5 axis milling considering a CNC Vertical Machining Center (VMC) to digitally twin milling process. Both the CAD modelling and manufacturing process plans including tool path generation are captured through journaling and customized / improved using the Application Programmable Interface's (API's) to suit the present scope. In this paper, the first part on CAD modelling and manufacturing simulation methodologies are discussed through validating the digital twining concept in a virtual environment. The work is developed with the focus to help industries moving towards Industry 4.0 and requiring a constant design improvement in their products. It is by emphasizing the importance of digital twinning concept where a concurrent verification of design and manufacturing process can be achieved