Fast Cutter Workpiece Engagement Estimation Method for Prediction of Instantaneous Cutting Force in Continuous Multi-Axis Controlled Machining

In order to realize high productivity in rough machining processes, a fast simulation system is needed for multi axis controlled machining to predict instantaneous cutting force. The new efficient algorithm to estimate an engagement between the end mill cutter and the machined workpiece in continuous multi axis controlled machining processes is proposed. In order to shorten calculation time for the engagement area, and to improve the real-time prediction of instantaneous cutting force, a new concept is introduced for adapting ultra-parallel processing technology. The proposed method assumes the engagement as a large number of divisions located on the locus of cutting edges. The inclusion estimation process between an estimation point in each division and the machined workpiece volume is resolved into two kinds of simple inclusion estimation – and between the estimation point and tool swept volume and the other between the estimation point and initial workpiece shape. In this paper, a new prototype system based on parallel processing technology known as the general purposed graphic processing unit (GPGPU) is developed and the proposed algorithm is verified with the prototype system. The system shows good performance for complicated NC programs generated by commercial CAM system and realizes real-time simulation of instantaneous cutting force.

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Real-Time Augmented Reality Physics Simulator for Education

Applied Sciences ◽

10.3390/app9194019 ◽

2019 ◽

Vol 9 (19) ◽

pp. 4019 ◽

Cited By ~ 2

Author(s):

Sung ◽

Ma ◽

Choi ◽

Hong

Keyword(s):

Parallel Processing ◽

Augmented Reality ◽

Real Time ◽

Physics Education ◽

Questionnaire Survey ◽

Depth Image ◽

Processing Unit ◽

Soft Body ◽

Augmented Reality System ◽

Volumetric Objects

Physics education applications using augmented reality technology, which has been developed extensively in recent years, have a lot of restrictions in terms of performance and accuracy. The purpose of our research is to develop a real-time simulation system for physics education that is based on parallel processing. In this paper, we present a video see-through AR (Augmented Reality) system that includes an environment recognizer using a depth image of Microsoft’s Kinect V2 and a real-time soft body simulator based on parallel processing using GPU (Graphic Processing Unit). Soft body simulation can provide more realistic simulation results than rigid body simulation, so it can be more effective in systems for physics education. We have designed and implemented a system that provides the physical deformation and movement of 3D volumetric objects, and uses them in education. To verify the usefulness of the proposed system, we conducted a questionnaire survey of 10 students majoring in physics education. As a result of the questionnaire survey, 93% of respondents answered that they would like to use it for education. We plan to use the stand-alone AR device including one or more cameras to improve the system in the future.

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Customized End Milling Operation of Dental Artificial Crown Without CAM Operation

International Journal of Automation Technology ◽

10.20965/ijat.2018.p0947 ◽

2018 ◽

Vol 12 (6) ◽

pp. 947-954 ◽

Cited By ~ 2

Author(s):

Isamu Nishida ◽

◽

Ryo Tsuyama ◽

Ryuta Sato ◽

Keiichi Shirase

Keyword(s):

Cutting Force ◽

Real Time ◽

End Milling ◽

Feed Speed ◽

High Productivity ◽

Nc Program ◽

Milling Operation ◽

Machine Control ◽

Copy Milling ◽

Tool Motion

A new methodology to generate instruction commands for real-time machine control instead of preparing NC programs is developed under the CAM-CNC integration concept. A machine tool based on this methodology can eliminate NC program preparation, achieve cutting process control, reduce production lead time, and realize an autonomous distributed factory. The special feature of this methodology is the generation of instruction commands in real time for the prompt machine control instead of NC programs. Digital Copy Milling (DCM), which digitalizes copy milling, is realized by referring only to the CAD model of the product. Another special feature of this methodology is the control of the tool motion according to the information predicted by a cutting force simulator. This feature achieves both the improvement in the machining efficiency and the avoidance of machining trouble. In this study, the customized end milling operation of a dental artificial crown is realized as an application using the new methodology mentioned above. In this application, the CAM operation can be eliminated for the NC program generation, and tool breakage can be avoided based on the tool feed speed control from the predicted cutting force. The result shows that the new methodology has good potential to achieve customized manufacturing, and can realize both high productivity and reliable machining operation.

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Real-Time Cutting Force Prediction and Cutting Force Coefficient Determination during Machining Processes

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.223.85 ◽

2011 ◽

Vol 223 ◽

pp. 85-92 ◽

Cited By ~ 1

Author(s):

Balázs Tukora ◽

Tibor Szalay

Keyword(s):

Cutting Force ◽

Real Time ◽

Cutting Forces ◽

End Milling ◽

Orthogonal Cutting ◽

Machining Process ◽

Work Piece ◽

Processing Unit ◽

Cutting Force Prediction ◽

Force Prediction

In this paper a new method for instantaneous cutting force prediction is presented, in case of sculptured surface milling. The method is executed in a highly parallel manner by the general purpose graphics processing unit (GPGPU). As opposed to the accustomed way, the geometric information of the work piece-cutter touching area is gained directly from the multi-dexel representation of the work-piece, which lets us compute the forces in real-time. Furthermore a new procedure is introduced for the determination of the cutting force coefficients on the basis of measured instantaneous or average orthogonal cutting forces. This method can determine the shear and ploughing coefficients even while the cutting geometry is continuously altering, e.g. in the course of multi-axis machining. In this way the cutting forces can be predicted during the machining process without a priori knowledge of the coefficients. The proposed methods are detailed and verified in case of ball-end milling, but the model also enables the applying of general-end cutters.

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Live, Video-Rate Super-Resolution Microscopy Using Structured Illumination and Rapid GPU-Based Parallel Processing

Microscopy and Microanalysis ◽

10.1017/s1431927611000158 ◽

2011 ◽

Vol 17 (2) ◽

pp. 191-196 ◽

Cited By ~ 3

Author(s):

Jonathan Lefman ◽

Keana Scott ◽

Stephan Stranick

Keyword(s):

Parallel Processing ◽

Real Time ◽

Super Resolution ◽

Fold Increase ◽

Frame Rate ◽

Processing Unit ◽

Structured Illumination ◽

Structured Illumination Microscopy ◽

Multiprocessor Computer ◽

Computational Overhead

AbstractStructured illumination fluorescence microscopy is a powerful super-resolution method that is capable of achieving a resolution below 100 nm. Each super-resolution image is computationally constructed from a set of differentially illuminated images. However, real-time application of structured illumination microscopy (SIM) has generally been limited due to the computational overhead needed to generate super-resolution images. Here, we have developed a real-time SIM system that incorporates graphic processing unit (GPU) based in-line parallel processing of raw/differentially illuminated images. By using GPU processing, the system has achieved a 90-fold increase in processing speed compared to performing equivalent operations on a multiprocessor computer—the total throughput of the system is limited by data acquisition speed, but not by image processing. Overall, more than 350 raw images (16-bit depth, 512 × 512 pixels) can be processed per second, resulting in a maximum frame rate of 39 super-resolution images per second. This ultrafast processing capability is used to provide immediate feedback of super-resolution images for real-time display. These developments are increasing the potential for sophisticated super-resolution imaging applications.

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An economic parallel processing technology for faster than real-time transient stability simulation

European Transactions on Electrical Power ◽

10.1002/etep.4450130205 ◽

2003 ◽

Vol 13 (2) ◽

pp. 105-112 ◽

Cited By ~ 3

Author(s):

S. Beaudin ◽

R. J. Marceau ◽

G. Bois ◽

Y. Savaria ◽

N. Kandil

Keyword(s):

Parallel Processing ◽

Real Time ◽

Transient Stability ◽

Processing Technology

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GPU-Based Real-Time Occlusion in an Immersive Augmented Reality Environment

Journal of Computing and Information Science in Engineering ◽

10.1115/1.3130144 ◽

2009 ◽

Vol 9 (2) ◽

Cited By ~ 5

Author(s):

Yuzhu Lu ◽

Shana Smith

Keyword(s):

Virtual Reality ◽

Augmented Reality ◽

Real Time ◽

Graphic Processing Unit ◽

Prototype System ◽

Processing Unit ◽

Virtual Objects ◽

Remote Cameras ◽

Real Scene ◽

And Performance

In this paper, we present a prototype system, which uses CAVE-based virtual reality to enhance immersion in an augmented reality environment. The system integrates virtual objects into a real scene captured by a set of stereo remote cameras. We also present a graphic processing unit (GPU)-based method for computing occlusion between real and virtual objects in real time. The method uses information from the captured stereo images to determine depth of objects in the real scene. Results and performance comparisons show that the GPU-based method is much faster than prior CPU-based methods.

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Real-Time Cutting Force/Torque Prediction During Turning

International Journal of Automation Technology ◽

10.20965/ijat.2012.p0669 ◽

2012 ◽

Vol 6 (5) ◽

pp. 669-674 ◽

Cited By ~ 3

Author(s):

Kazuto Enomoto ◽

◽

Masaya Takei ◽

Yasuhiro Kakinuma

Keyword(s):

Cutting Force ◽

Real Time ◽

Process Monitoring ◽

Disturbance Observer ◽

Shear Angle ◽

Force Estimation ◽

Monitoring Methods ◽

Machining Processes ◽

The Cost

The automation of machining processes requires highly accurate process monitoring. However, the use of additional sensors leads to a significant increase in the cost and reduces the stiffness and reliability of mechanical systems. Hence, we propose a system called the cutting force observer, which uses a sensor-less and real-time cutting force estimation methodology based on the disturbance observer theory. Monitoring methods using the cutting force observer may enhance the productivity during turning. One of the parameters that significantly affect the cutting process is the shear angle. The determination of the shear angle is very important as it can be used for identifying the machining conditions. In this study, an external sensor-less monitoring system of the shear angle during turning is developed, and its performance is evaluated.

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Real-time machine simulation using cutting force calculation based on a voxel material removal model

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-019-04418-2 ◽

2019 ◽

Vol 105 (5-6) ◽

pp. 2321-2328

Author(s):

Marco Witt ◽

Marco Schumann ◽

Philipp Klimant

Keyword(s):

Cutting Force ◽

Real Time ◽

Material Removal ◽

Work Piece ◽

Time Machine ◽

Machining Processes ◽

Starting Point ◽

Material Removal Model ◽

Machine Simulation ◽

Force Calculation

Abstract Machining processes must be adjusted regarding tolerances in dimension and shape to fulfill product requirements. For this purpose, machine simulations are used to allow a preliminary characterization of the given process, thus minimizing the number of physical prototypes and scrap parts. However, these simulations are either extremely specialized for single problems, e.g., dynamic machine behavior, or they are simplified to a kinematic simulation of the machine without considering the machine behavior at all. This article presents a new approach for a real-time machine simulation by combining four types of simulations to close this gap. This proposed approach uses a voxel-based material removal inside a kinematic machine simulation as input parameters for a cutting force calculation. Afterwards, the forces are applied to a multi-body simulation of the static machine behavior. Starting point of the simulation is a hardware-in-the-loop coupling of a real CNC and a real-time visualization of a virtual machine tool. The simulation is experimental verified by comparing the simulated cutting forces and displacements with the measured forces during the process and the resulting shape of the manufactured work piece. The presented conclusions show the general applicability of the proposed method for the simulation of milling processes.

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