scholarly journals Integrated Design of Spindle Speed Modulation and Cutting Vibration Suppression Controls Using Disturbance Observer for Thread Milling

Materials ◽  
2021 ◽  
Vol 14 (21) ◽  
pp. 6656
Author(s):  
Syh-Shiuh Yeh ◽  
Chai-Wei Chen
Keyword(s):  
Disturbance Observer ◽  
Vibration Suppression ◽  
Integrated Design ◽  
Spindle Speed ◽  
Numerical Control ◽  
Manufacturing Efficiency ◽  
Speed Modulation ◽  
Cutting Vibrations ◽  
Thread Milling ◽  
Cutting Vibration

In thread milling, there exists a trade-off between thread manufacturing efficiency and thread quality. In this study, an integrated design of spindle speed modulation (SSM) and cutting vibration suppression (CVS) controls using a disturbance observer were developed to simultaneously ensure superior quality and high manufacturing efficiency. The proposed integrated design not only controls the cutting torque while suppressing cutting vibrations but also ensures cost-effectiveness and mitigates the installation problems prevalent in existing sensor-based methods. The SSM control uses a disturbance observer to estimate the cutting torque required on the spindle during thread milling. The estimated cutting torque is used as a feedback signal so that the SSM control can modulate the spindle speed to make the cutting torque achieve a preset torque command. To further avoid cutting vibrations in thread milling, the CVS control analyzes the estimated cutting torque, detects the occurrence of cutting vibrations, and then adjusts the torque command of the SSM control to suppress the cutting vibrations. In this study, thread milling experiments were performed on a computer numerical control milling machine using the workpiece with stacked materials. The feasibility and performance of the proposed integrated design were validated by experiments.

Adaptive neuro-fuzzy fusion of multi-sensor data for monitoring of CNC machining

Sensor Review ◽  
2017 ◽  
Vol 37 (1) ◽  
pp. 78-81 ◽  
Author(s):  
Srdjan Jovic ◽  
Obrad Anicic ◽  
Milivoje Jovanovic
Keyword(s):  
Selection Process ◽  
Spindle Speed ◽  
Cnc Machining ◽  
Numerical Control ◽  
Periodic Component ◽  
Sensor Data ◽  
Depth Of Cut ◽  
Inference System ◽  
Content Type ◽  
Neuro Fuzzy

Purpose Acoustic emission (AE) could be used for prevention and detection of tool errors in Computer Numerical Control (CNC) machining. The purpose of this study is to analyze the AE form of CNC machining operations. Design/methodology/approach Experimental measurements were performed with three sensors on the CNC lathe to collect the data of the CNC machining. Adaptive neuro-fuzzy inference system (ANFIS) was applied for the fusion from the sensors’ signals to determine the strength of the signal periodic component among the sensors. Findings There were three inputs, namely, spindle speed, feed rate and depth of cut. ANFIS was also used to determine the inputs’ influence on the prediction of strength of the signal periodic component. Variable selection process was used to select the most dominant factors which affect the prediction of strength of the signal periodic component. Originality/value Results were shown that the spindle speed has the most dominant effect on the strength of the signal periodic component.

An Integrated Design for a CNC Machine

2014 ◽  
pp. 254-265
Author(s):  
Amro Shafik ◽  
Salah Haridy
Keyword(s):  
Low Cost ◽  
Integrated Design ◽  
Numerical Data ◽  
Open Loop ◽  
Numerical Control ◽  
Future Research ◽  
Cnc Machine ◽  
Loop Control ◽  
Loop Control System ◽  
Stepper Motors

Computer Numerical Control (CNC) is a technology that converts coded instructions and numerical data into sequential actions that describe the motion of machine axes or the behavior of an end effector. Nowadays, CNC technology has been introduced to different stages of production, such as rapid prototyping, machining and finishing processes, testing, packaging, and warehousing. The main objective of this chapter is to introduce a methodology for design and implementation of a simple and low-cost educational CNC prototype. The machine consists of three independent axes driven by stepper motors through an open-loop control system. Output pulses from the parallel port of Personal Computer (PC) are used to drive the stepper motors after processing by an interface card. A flexible, responsive, and real-time Visual C# program is developed to control the motion of the machine axes. The integrated design proposed in this chapter can provide engineers and students in academic institutions with a simple foundation to efficiently build a CNC machine based on the available resources. Moreover, the proposed prototype can be used for educational purposes, demonstrations, and future research.

Similarity-Based Integrated Scheduling of Machining Processes in the NC Resource Grid

2010 ◽  
Vol 97-101 ◽  
pp. 2403-2406
Author(s):  
Ya Bo Luo ◽  
Ming Chun Tang
Keyword(s):  
Numerical Control ◽  
Grid System ◽  
Machining Processes ◽  
Integrated Scheduling ◽  
Similarity Principle ◽  
Manufacturing Efficiency ◽  
Scheduling Model ◽  
Delivery Date ◽  
Complex Constraints ◽  
Optimum Solution

Grouping the similar processes is a good approach to improve the manufacturing efficiency, however, which is facing with two difficulties of the group automation and the constraints coupling. Regarding the numerical control (NC) machines and tasks as a grid system, this paper proposes a similarity-based tactic to solve the above difficulties. First, the methodology for analyzing the similarity among NC tasks is proposed to implement group automation taking the similarity principle as theory foundation. Second, based on the results drawn from the first step, the complex constraints including similarity constraints, delivery date constraints, and serial constraints are coupled to develop an integrated scheduling model. Finally, the integrated model is solved and the optimum solution is gotten using a specialized ants algorithm.

Estimation of fractal dimension and surface roughness based on material characteristics and cutting conditions in the end milling of carbon steels

2015 ◽  
Vol 231 (8) ◽  
pp. 1423-1437 ◽  
Author(s):  
Xue Zuo ◽  
Hua Zhu ◽  
Yuankai Zhou ◽  
Jianhua Yang
Keyword(s):  
Surface Roughness ◽  
Fractal Dimension ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Parameters ◽  
Carbon Steels ◽  
Spindle Speed ◽  
Numerical Control ◽  
Material Hardness ◽  
Milled Surface

Cutting parameters and material properties have important effects on the quality of milled surface, which can be characterized by fractal dimension and surface roughness. The relationships between two surface parameters (surface roughness and fractal dimension) and material hardness, elongation, spindle speed and feed rate were investigated, respectively, in this study. Four carbon steels, that is, AISI 1020, Gr 50, 1045 and 1566, were milled with five spindle speeds and four feed rates on a computer numerical control machine. The surface topographies were measured with a three-dimensional profiler. The surface profiles were obtained by re-sampling the data points on the surface topography in the measurement direction. The surface roughness and fractal dimension were calculated from the two-dimensional profiles, where the fractal dimension was obtained by the root-mean-square method. The results showed that for specific spindle speed and feed rate, the roughness of the milled surface decreased with the workpiece hardness, whereas the elongation and fractal dimension increased with the hardness. Based on the material hardness and elongation, spindle speed and feed rate, empirical formulae were established to quantitatively estimate the surface roughness and fractal dimension. Moreover, the spindle speed and feed rate can be easily calculated from the empirical formulae to achieve a surface with the desired surface roughness and fractal dimension. The empirical formulae have been demonstrated with the experiments and were shown to be applicable in estimating the surface roughness and fractal dimension for all carbon steels in end milling. The results are instructive for the fractal dimension estimation of the machined surfaces of carbon steel, which has not been previously studied.

scholarly journals Surface roughness of thermally treated wood cut with different parameters in CNC router machine

BioResources ◽  
2021 ◽  
Vol 16 (3) ◽  
pp. 5133-5147
Author(s):  
Hüseyin Pelit ◽  
Mustafa Korkmaz ◽  
Mehmet Budakçı
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Treatment Temperature ◽  
Spindle Speed ◽  
Numerical Control ◽  
Machining Parameters ◽  
End Mill ◽  
Cnc Machine ◽  
Cnc Router ◽  
Thermally Treated

The effects of different machining parameters on surface roughness values of thermally treated pine, beech, and linden woods cut in a computer numerical control (CNC) router machine were examined. Wood specimens were thermally treated at 170, 190, and 210 °C for 2 h. Then, specimens were cut in the radial and tangential directions with three different spindle speeds (12000, 15000, and 18000 rpm) and three different feed rates (3000, 4000, and 6000 mm/min) using two different end mill tools (spiral and straight) on the CNC machine. The end mill type significantly affected the roughness values of the untreated and thermally treated specimens in both directions. Lower roughness values were found in the specimens (especially pine) machined with the straight end mill compared to those machined with the spiral end mill. Roughness generally decreased in the thermally treated specimens. However, thermal treatment temperature did not have a notable effect on roughness. As the spindle speed increased, the roughness values of all specimens decreased. In contrast, as the feed rate increased, the roughness values increased. Therefore, the end mill type, feed rate, and spindle speed were the most influential parameters on the roughness.

scholarly journals The influence of machining parameters on surface roughness of MDF in milling operation

BioResources ◽  
2019 ◽  
Vol 14 (2) ◽  
pp. 3266-3277
Author(s):  
Ümmü K. İşleyen ◽  
Mehmet Karamanoğlu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Medium Density Fiberboard ◽  
Spindle Speed ◽  
Numerical Control ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Milling Operation ◽  
Four Levels ◽  
Tool Diameter

This paper examined the effect of machining parameters on surface roughness of medium density fiberboard (MDF) machined using a computer numerical control (CNC) router. The machining parameters such as spindle speed, feed rate, depth of cut, and tool diameter were examined for milling. The experiments were conducted at two levels of spindle speeds, four levels of feed rates, two levels of tool diameters, and two levels of axial depths of cut. The surface roughness values of MDF grooved by CNC were measured with stylus-type equipment. Statistical methods were used to determine the effectiveness of the machining parameters on surface roughness. The influence of each milling parameter affecting surface roughness was analyzed using analysis of variance (ANOVA). The significant machining parameters affecting the surface roughness were the feed rate, spindle speed, and tool diameter (p < 0.05). There was no significant influence of axial depth of cut on the surface roughness. The surface roughness decreased with increasing spindle speed and decreasing feed rate. The value of surface roughness increased with the increase of tool diameter.

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