Investigating Cyber-Physical Threats of Numerically Controlled Manufacturing Processes

2020 ◽  
Author(s):  
Joseph Piacenza ◽  
Kenneth J. Faller ◽  
Bradley Regez ◽  
Luisfernando Gomez
Keyword(s):  
Manufacturing Systems ◽  
Ex Situ ◽  
Raspberry Pi ◽  
Manufacturing Processes ◽  
Device Design ◽  
Cnc Machine ◽  
Machining Processes ◽  
Machine Performance ◽  
Design Iteration ◽  
Lathe Machine

Abstract Motivated by cyber-physical vulnerabilities in precision manufacturing processes, there is a need to externally examine the operational performance of Computer Numerically Controlled (CNC) manufacturing systems. The overarching objective of this work is to design and fabricate a proof-of-concept CNC machine evaluation device, ultimately re-configurable to the mill and lathe machine classes. This device will assist in identifying potential cyber-physical security threats in manufacturing systems by identifying perturbations, outside the expected variations of machining processes, and comparing the desired command inputted into the numerical controller and the actual machine performance (e.g., tool displacement, frequency). In this directed research, a device design is presented based on specific performance requirements provided by the project sponsor. The first design iteration is tested on a Kuka KR 6 R700 series robotic arm, and machine movement comparisons are performed ex-situ using Keyence laser measurement sensors. Data acquisition is performed with a Raspberry Pi 4 microcomputer, controlled by custom, cross-platform Python code, and includes a touch screen human-computer interface. A device design adapted for a CNC mill is also presented, and the Haas TM-2 is used as a case study, which can be operated by technicians to check CNC machine accuracy, as needed, before a critical manufacturing process.

VERIFICATION OF NUMERICALLY CONTROLLED MANUFACTURING PROCESSES, TOWARD IDENTIFYING CYBER-PHYSICAL THREATS

2021 ◽  
pp. 1-33
Author(s):  
Joseph R Piacenza ◽  
Kenneth John Faller ◽  
Bradley Regez ◽  
Luisfernando Gomez
Keyword(s):  
Manufacturing Systems ◽  
Ex Situ ◽  
Raspberry Pi ◽  
Manufacturing Processes ◽  
Device Design ◽  
Cnc Machine ◽  
Machining Processes ◽  
Machine Performance ◽  
Design Iteration ◽  
Lathe Machine

Abstract Motivated by cyber-physical vulnerabilities in precision manufacturing processes, there is a need to externally examine the operational performance of Computer Numerically Controlled (CNC) manufacturing systems. The overarching objective of this work is to design and fabricate a proof-of-concept CNC machine evaluation device, ultimately re-configurable to the mill and lathe machine classes. This device will assist in identifying potential cyber-physical security threats in manufacturing systems by identifying perturbations, outside the expected variations of machining processes, and comparing the desired command inputted into the numerical controller and the actual machine performance (e.g., tool displacement, frequency). In this paper, a method and device design, based on specific performance requirements provided by the project sponsor, is presented and tested. These results will be used to improve future iterations of the method and device design. The first design iteration is tested on a Kuka KR 6 R700 series robotic arm, and machine movement comparisons are performed ex-situ using Keyence laser measurement sensors. Data acquisition is performed with a Raspberry Pi 4 microcomputer, controlled by custom, cross-platform Python code, and includes a touch screen Human-Computer Interface (HCI). A device design adapted for a CNC mill is also presented, and the Haas TM-2 is used as a case study, which can be operated by technicians to evaluate CNC machine accuracy, as needed, before a critical manufacturing process.

Modeling and Identification of Feed Drive Kinematics and Cycle Time Calculation

Manufacturing ◽  
2003 ◽  
Author(s):  
Wencai Wang ◽  
Derek M. Yip-Hoi
Keyword(s):  
Machine Tool ◽  
Cycle Time ◽  
Manufacturing Systems ◽  
Kinematic Model ◽  
Cnc Machine ◽  
Machining Processes ◽  
Calculation Algorithm ◽  
Motion Data ◽  
Feed Drive ◽  
Time Calculation

Cycle time calculation plays a major role in the design of manufacturing systems. Accurate estimates are needed to correctly determine the capacity of a line in terms of the number of machines that must be purchased. Over estimation results in excess capacity and under estimation leads to unsatisfied demand. Due to the high automation and cutting speeds of modern machining processes, cycle time calculation must consider both the timing of various machining actions and the kinematics of feed motions. This paper presents a cycle time calculation algorithm that gives accurate cycle time results by considering the effects of jerk and acceleration of the machine tool drives. The kinematic model for axis motion is based on trapezoidal acceleration profiles along the toolpaths. Based on this model, an algorithm for identifying the kinematic parameters has been developed. This algorithm has the advantage of utilizing a minimal set of axis motion data thus reducing the amount of data that must be collected from experiments by the machine tool vendor or the machine tool’s enduser. The proposed cycle time calculation algorithm has been verified in machining a V6 cylinder head on a four axis CNC machine.

Using Virtual Reality in the Teaching of Manufacturing Processes with Material Removal in CNC Machine-Tools

2011 ◽  
Vol 692 ◽  
pp. 112-119 ◽  
Author(s):  
Alfredo Sanz ◽  
Ignaciof González ◽  
Agustin Javier Castejón ◽  
Jose Leopoldo Casado
Keyword(s):  
Virtual Reality ◽  
Virtual Machine ◽  
Machine Tools ◽  
Material Removal ◽  
Teaching Practice ◽  
Numerical Control ◽  
Cnc Machine Tools ◽  
Manufacturing Processes ◽  
Cnc Machine ◽  
Machining Processes

This paper presents a methodology for the incorporation of a Virtual Reality development applied to the teaching of manufacturing processes, namely the group of machining processes in numerical control of machine tools. The paper shows how it is possible to supplement the teaching practice through virtual machine-tools whose operation is similar to the 'real' machines while eliminating the risks of use for both users and the machines.

Machining Accuracy Analysis for Computer-aided Fixture Design Verification

1996 ◽  
Vol 118 (3) ◽  
pp. 289-300 ◽  
Author(s):  
Y. Rong ◽  
Y. Bai
Keyword(s):  
Manufacturing Systems ◽  
Cnc Machine Tools ◽  
Machining Accuracy ◽  
Fixture Design ◽  
Accuracy Analysis ◽  
Design Verification ◽  
Cnc Machine ◽  
Machining Processes ◽  
Machining Errors ◽  
Computer Aided

This paper presents a machining accuracy analysis for computer-aided fixture design verification. While discussing the utilization of CNC machine tools and machining centers, machining errors are described in terms of deterministic and random components and analyzed on the bases of their sources, where high machining accuracy and multi-operation under a single setup become major characteristics of manufacturing systems. In machining processes, a resultant dimension may be generated in terms of several relevant dimensions. The dependency of variation among these dimensions is examined and the relationships of locating datum and machining surfaces are analyzed. Variation among linear and angular dimensions are considered. Five basic models of dimension variation relationships are proposed to estimate the machining error, where different formulas of resultant dimension variation are given for different combinations of variation among relevant dimensions. A datum-machining surface relationship graph (DMG) is developed to represent the dependent relationships. A matrix-based reasoning algorithm is designed to search for the shortest path in the DMG. Once the relationship between a specified pair of surfaces is identified, different models of corresponding relationships may be utilized to estimate the possible machining errors which can be used to compare the fixturing accuracy requirement.

scholarly journals INTELLIGENT MACHINING: REAL-TIME TOOL CONDITION MONITORING AND INTELLIGENT ADAPTIVE CONTROL SYSTEMS

2018 ◽  
Vol Vol.18 (No.1) ◽  
pp. 5-18 ◽  
Author(s):  
M. HASSAN ◽  
A. SADEK ◽  
M.H. ATTIA ◽  
V. THOMSON
Keyword(s):  
Adaptive Control ◽  
Real Time ◽  
Condition Monitoring ◽  
High Speed ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Tool Condition Monitoring ◽  
Cnc Machine ◽  
Machining Processes ◽  
Tool Condition

Unmanned manufacturing systems has recently gained great interest due to the ever increasing requirements of optimized machining for the realization of the fourth industrial revolution in manufacturing ‘Industry 4.0’. Real-time tool condition monitoring (TCM) and adaptive control (AC) machining system are essential technologies to achieve the required industrial competitive advantage, in terms of reducing cost, increasing productivity, improving quality, and preventing damage to the machined part. New AC systems aim at controlling the process parameters, based on estimating the effects of the sensed real-time machining load on the tool and part integrity. Such an aspect cannot be directly monitored during the machining operation in an industrial environment, which necessitates developing new intelligent model-based process controllers. The new generations of TCM systems target accurate detection of systematic tool wear growth, as well as the prediction of sudden tool failure before damage to the part takes place. This requires applying advanced signal processing techniques to multi-sensor feedback signals, in addition to using ultra-high speed controllers to facilitate robust online decision making within the very short time span (in the order of 10 ms) for high speed machining processes. The development of new generations of Intelligent AC and TCM systems involves developing robust and swift communication of such systems with the CNC machine controller. However, further research is needed to develop the industrial internet of things (IIOT) readiness of such systems, which provides a tremendous potential for increased process reliability, efficiency and sustainability.

scholarly journals Improving the Performance of Steel Machining Processes through Cutting by Vibration Control

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5712
Author(s):  
Mihaela Oleksik ◽  
Dan Dobrotă ◽  
Mădălin Tomescu ◽  
Valentin Petrescu
Keyword(s):  
Fourier Transformation ◽  
Vibration Analysis ◽  
Cutting Tool ◽  
Cutting Process ◽  
Manufacturing Processes ◽  
Machining Processes ◽  
Short Time ◽  
Short Time Fourier Transformation ◽  
Dynamic Phenomena

Machining processes through cutting are accompanied by dynamic phenomena that influence the quality of the processed surfaces. Thus, this research aimed to design, make, and use a tool with optimal functional geometry, which allowed a reduction of the dynamic phenomena that occur in the cutting process. In order to carry out the research, the process of cutting by front turning with transversal advance was taken into account. Additionally, semi-finished products with a diameter of Ø = 150 mm made of C45 steel were chosen for processing (1.0503). The manufacturing processes were performed with the help of two tools: a cutting tool, the classic construction version, and another that was the improved construction version. In the first stage of the research, an analysis was made of the vibrations that appear in the cutting process when using the two types of tools. Vibration analysis considered the following: use of the Fast Fourier Transform (FFT) method, application of the Short-Time Fourier-Transformation (STFT) method, and observation of the acceleration of vibrations recorded during processing. After the vibration analysis, the roughness of the surfaces was measured and the parameter Ra was taken into account, but a series of diagrams were also drawn regarding the curved profiles, filtered profiles, and Abbott–Firestone curve. The research showed that use of the tool that is the improved constructive variant allows accentuated reduction of vibrations correlated with an improvement of the quality of the processed surfaces.

scholarly journals Configuring the programming and control systems for a mini 3-axis CNC machine tool on the Raspberry PI platform

Tehnika ◽  
2019 ◽  
Vol 74 (6) ◽  
pp. 823-831
Author(s):  
Saša Živanović ◽  
Nikola Vorkapić ◽  
Zoran Dimić
Keyword(s):  
Machine Tool ◽  
Control Systems ◽  
Raspberry Pi ◽  
Cnc Machine Tool ◽  
Cnc Machine ◽  
And Control

Lyapunov Control Strategy for Thermoelectric Cooler Activating an Ice-Clamping System

2018 ◽  
Vol 10 (4) ◽  
Author(s):  
Alexandra Mironova ◽  
Paolo Mercorelli ◽  
Andreas Zedler
Keyword(s):  
Manufacturing Systems ◽  
Control Strategies ◽  
Industrial Applications ◽  
Machining Process ◽  
Free Form ◽  
Cooling Power ◽  
Machining Processes ◽  
Clamping System ◽  
Ice Strength ◽  
Free Form Surfaces

Deformation-free clamping plays an important role in manufacturing systems helping to ensure zero-defect production. The fixture of workpieces during machining processes poses challenges not only for microparts but also for thin-walled pieces or free-form surfaces in macromanufacturing. To address this challenge, a nontraditional adhesive technique, using frozen water to clamp, is introduced in this paper. By increasing the cooling power and thus reducing the temperature of the clamping plate, higher adhesive ice strength and, therefore, a safer clamping system during machining process, can be achieved. The objective of this investigation is to ensure a stable low temperature and to compensate for thermal disturbances. Thanks to their structural robustness, Lyapunov-based control strategies demonstrate an appropriate capability to achieve these results in real industrial applications. Model design of the clamping system as well as simulation and experimental results are shown and discussed.

Process-Oriented Tolerance Synthesis for Multistage Manufacturing Systems

2000 ◽  
Author(s):  
Yu Ding ◽  
Jionghua Jin ◽  
Dariusz Ceglarek ◽  
Jianjun Shi
Keyword(s):  
Product Design ◽  
Process Design ◽  
Manufacturing Systems ◽  
Minimum Cost ◽  
Manufacturing Processes ◽  
Industrial Case Study ◽  
Multistage Manufacturing ◽  
Process Oriented ◽  
Design Characteristics

Abstract In multistage manufacturing systems, quality of final products is strongly affected not only by product design characteristics but also by key process design characteristics. However, historically, tolerance research has primarily focused on allocating tolerances based on product design characteristics for each component. Currently, there is no analytical approach for multistage manufacturing processes to optimally allocate tolerances to integrate product and process characteristics at minimum cost. One of the major obstacles is that the relationship between tolerances of process and product characteristics is not well understood and modeled. Under this motivation, this paper aims at presenting a framework addressing the process-oriented (rather than product-oriented) tolerancing technique for multistage manufacturing processes. Based on a developed state space model, tolerances of process design characteristics at each fabrication stage are related to the quality of final product. All key elements in the framework are described and then derived for a multistage assembly process. An industrial case study is used to illustrate the proposed approach.

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