Development of an Open Soft CNC System Based on STEP-NC and Function Blocks

Modern manufacturing industries have put on increasing demands on computer numerical controllers (CNC) for it to be able to work with and process higher level input data described using languages such as STEP-NC, rather than the outdated G-codes. The research work described in this paper is about the development of a soft CNC controller that can process STEP-NC (ISO 14649) data. Function blocks (IEC 61499) are also used as the interface between the STEP-NC data model and the controller. The layered STEP-NC/FB architecture is proposed, which simplifies the design of the controller with layers responsible for data processing, data storage and execution. With the object-oriented, Model-View-Control design pattern, the STEP-NC/FB architecture supports the design framework, in which simulation of the machining becomes a natural and inherent part of the design process, with seamless transition from simulation to actual machining

A REVIEW OF INTELLIGENT CNC CONTROLLER DEVELOPMENT BASED ON STEP-NC

In the contemporary Computer Numeric Controlled (CNC) machine tools of Computer Aided Manufacturing (CAM) and CNC process conducted by a number of inter-related operations and parameters using G Codes and M codes set as RS274 or ISO 6983 standard. However, this programming language does not explicitly relate to each other to have control of arbitrary locations other than the motion of the block-by-block. STEP-NC is the extension to STEP, Standard for Exchange Product model data. This determines the neutral data format for digital information from a product. STEP-NC standard is on how information about CNC machining can be added to parts represented in the STEP product model data. In this paper is to review and explore the making of interoperable CNC manufacturing is then provided relating milling, turning, turn-mill through the development of information models for products, processes and new machining system controller developed base on new standard ISO 14649 standard and ISO 10303, which related to data modeling for CNC features, process planning, and machine tool. It is expected that this paper will meet a step towards the requirements for global interoperable manufacturing for real-life machining system

Optimization of Machining Parameters in Turning Operation Using PSO and AIS Algorithms: A Survey

In recent manufacturing, the optimization of turning processes is one of important problems which aim to increase competitiveness and product quality. However, the choice of optimal machining parameters is difficult and complex. Traditionally, the selections is heavily relies on trial and error methods which is tedious and unreliable. Metaheuristics methods have been proposed over the last decade to overcome these problems. This paper presents a survey for optimizing the parameters of turning operation using Particle Swarm Optimization (PSO) and Artificial Immune System (AIS). This study deals with different machining performance in turning operation like surface roughness, material removal rate , tool wear , tool life, production cost, machining time and cutting temperature. Most papers in the field of turning parameters optimization are based on (PSO) algorithms, but only a few efforts that are using (AIS) algorithms. In addition, there is a gap of several machining operation parameters especially for cutting temperature optimization in turning operation using PSO and AIS

Investigation of cutting parameter and machine tool vibration effects using regression analysis to enhance part dimensional accuracy

Dimensional accuracy plays important criteria in producing high quality machined parts. This is a big challenge to manufacturers of precision components to produce good quality parts with minimum manufacturing error. The focus of this paper is to study the influence of the machine tool rigidity and cutting parameters on dimensional accuracy in turning operation. A method was prepared for identifying the factors effecting dimensional accuracy in a turning process. Experimental setup involved computerized numerical control (CNC) lathe machine, with VBMT 160404 carbide insert and mild steel, as cutting tool and workpiece respectively. The statistical analysis was used for analyzing and determining the accuracy of experimental data through Minitab statistical software. The regressions model was developed. The developed regression model could be used to predict the dimensional precision of the parts based on machine tool vibration and machining parameters during turning process. This is the aspect to be seriously considered and be applied in attaining sustainable machine tool development during design and development stage and its usage. This finding provides useful guidelines for manufacturers to produce high quality machined parts at minimum manufacturing cost. It was found that the cutting speed, feed rate, final part length, vibration x and vibration z have significant effects on dimensional accuracy of the machined parts

Linear regression and R-squared correlation analysis on major nuclear online plant cooling system

The primary cooling system is an integral part of a nuclear reactor that maintains reactor operational safety. It is essential to investigate the effects of the cooling system parameter before implementing predictive maintenance techniques in the reactor monitoring system. This paper presents a linear regression and R-squared correlation analysis of the nuclear plant cooling system parameter in the TRIGA PUSPATI Reactor in Malaysia. This research examines the primary cooling system's temperature, conductivity, and flow rate in maintaining the nuclear reactor. Data collection on the primary coolant system has been analyzed, and correlation analysis has been derived using linear regression and R-squared analysis. The result displays the correlation matrix for all sensors in the primary cooling system. The R-squared value for TT5 versus TT2 is 89%, TT5 versus TT3 is 94%, and TT5 against TT4 is 66% which shows an excellent correlation to the linear regression. However, the conductivity sensor CT1 does not correlate with other sensors in the system. The flow rate sensor FT1 positively correlates with the temperature sensor but does not correlate with the conductivity sensor. This finding can help to better develop the predictive maintenance strategy for the reactor monitoring program

Development of Driving Fatigue Strain Index for Reducing Accident Risk Among Drivers

Driving has become more important as this medium being practically, faster and cheaper in connecting human from one to other places. However, in some occurrences driving activity can cause disaster or death to human in daily life as they get fatigued while driving. Driving fatigue is one of the top contributor to the road crashes. Therefore this study is to develop a driving fatigue strain index (DFSI), collaborate with Decision Support System (DSS), to quantify the risk levels caused by driving activity, and to propose an appropriate solution in minimizing the number of road accidents caused by the driving fatigue. The decision support system provide fast and systematic analysis, and solutions to minimize the risk and the number of accidents associated with driving fatigue. The development of DFSI is based on risk factors associated with driving activity such as muscle activity, heart rate, hand grip force, seat pressure distribution, whole-body vibration, and driving duration. All risk factors are assigned with multipliers, and the DFSI is the output or result of those multipliers. The development of DFSI is essential to analyze the risk factors that would contribute significantly to discomfort and fatigue associated with driving. Besides, in the future this index will have a capability to recommend alternative solutions to minimize fatigue while driving

Investigation of cutting parameter and machine tool vibration effects using regression analysis to enhance part dimensional accuracy

Dimensional accuracy plays important criteria in producing high quality machined parts. This is a big challenge to manufacturers of precision components to produce good quality parts with minimum manufacturing error. The focus of this paper is to study the influence of the machine tool rigidity and cutting parameters on dimensional accuracy in turning operation. A method was prepared for identifying the factors effecting dimensional accuracy in a turning process. Experimental setup involved computerized numerical control (CNC) lathe machine, with VBMT 160404 carbide insert and mild steel, as cutting tool and workpiece respectively. The statistical analysis was used for analyzing and determining the accuracy of experimental data through Minitab statistical software. The regressions model was developed. The developed regression model could be used to predict the dimensional precision of the parts based on machine tool vibration and machining parameters during turning process. This is the aspect to be seriously considered and be applied in attaining sustainable machine tool development during design and development stage and its usage. This finding provides useful guidelines for manufacturers to produce high quality machined parts at minimum manufacturing cost. It was found that the cutting speed, feed rate, final part length, vibration x and vibration z have significant effects on dimensional accuracy of the machined parts

Design and Development of 3-Axis Benchtop CNC Milling Machine for Educational Purpose

The main factor in improving learning skills is providing students with hands-on laboratory experience, and the small-scale machine can accomplish academic programs requiring students to learn machining skills. This paper aims to design and develop a 3-axis CNC milling machine with a PC-based open architecture controller in a vertical position open frame structure. Some technical specifications were randomly selected based on the capabilities of similarly sized machines reviewed in previous work. The designed machine consisted of inexpensive off-the-shelf hardware components capable of machining the sample block with high cutting speed and reasonable precision. The accepted percentage error of circular and straightness test readings is below the set requirements. This machine is not intended for series production and precise machining. It can still effectively replace the high cost of commercial CNC machines and be used in any higher education institution offering technical courses

Design and Development of 3-Axis Benchtop CNC Milling Machine for Educational Purpose

The main factor in improving learning skills is providing students with hands-on laboratory experience, and the small-scale machine can accomplish academic programs requiring students to learn machining skills. This paper aims to design and develop a 3-axis CNC milling machine with a PC-based open architecture controller in a vertical position open frame structure. Some technical specifications were randomly selected based on the capabilities of similarly sized machines reviewed in previous work. The designed machine consisted of inexpensive off-the-shelf hardware components capable of machining the sample block with high cutting speed and reasonable precision. The accepted percentage error of circular and straightness test readings is below the set requirements. This machine is not intended for series production and precise machining. It can still effectively replace the high cost of commercial CNC machines and be used in any higher education institution offering technical courses

A Framework Of Next Generation Adaptive CNC Controller

Modern manufacturing industries have increasingly demanded to bring comprehensive input data described using high-level languages such as STEP-NC, rather than outdated G&M codes into computer numerical control machine tool levels. In current dynamic shop floor environments, predefined numerical control (NC) command generated in early stages is regularly found unusable or unsuitable for the dedicated resources, causing useless efforts used up in the initial process planning and NC code generation. This research aims to propose a new structure of an adaptive CNC controller by taking the advantages of well-known IEC61499 and STEP-NC standards.For realising adaptive CNC controller capability, integration of the native process planning decision-making function into CNC controller will be established. The activities such as cutting tool selection, machining parameter determination and toolpath generation will be issued automatically by the controller itself that subject to available online machine resources. The generic STEP-NC file is employed as data input and arranged accordingly in the IEC 61499 function block software editor. The system is developed in the JAVA environment by using proposed language