Research on Simulation of Virtual NC Lathe Machining Process

2014 ◽  
Vol 552 ◽  
pp. 381-386
Author(s):  
Li Bo Zhou ◽  
Fu Lin Xu ◽  
Zhi Xiong Shen
Keyword(s):  
High Efficiency ◽  
Physical Simulation ◽  
Shape Change ◽  
Strain Analysis ◽  
Machining Process ◽  
Machining Parameters ◽  
Nc Code ◽  
Cnc Programming ◽  
Simulation Functions ◽  
Simulation Results

Virtual NC lathe machining simulation system is carried out with Visual C++ and Open Inventor software. The system possesses visible UI, interactive inputting workpiece and machining parameters, the integration of geometric simulation and physical simulation, all the simulation functions including real-time display machining process, tool moving, workpiece geometry shape change, the generation and movement of iron simulation, workpiece pressure shape change could be realized. Tool temperature analysis and stress & strain analysis are simulated in the cutting process by FEM. The simulation results show the high efficiency of the simulation algorithm, reasonable simulation results, lifelike. The practice and training could be replaced by the virtual one. The system is applied to verification of NC code, quality evaluation of machine operators, operators, CNC programming staff training and other functions.

scholarly journals Research on Shape Change of Multimaterial Electrode for EDM

2019 ◽  
Vol 2019 ◽  
pp. 1-11
Author(s):  
Wenjian Wang ◽  
Yu Liu ◽  
Wenchao Zhang ◽  
Fujian Ma ◽  
Dapeng Yang ◽  
...  
Keyword(s):  
Material Removal ◽  
Shape Change ◽  
Pulse Discharge ◽  
Single Pulse ◽  
Machining Process ◽  
Die Steel ◽  
Electrode Shape ◽  
Simulation Strategy ◽  
Feed Strategy ◽  
Simulation Results

The shape change law of a multimaterial electrode in EDM was studied, and a cosimulation between ANSYS and MATLAB of electrode shape change of the multimaterial electrode and workpiece was established. Element birth and death in ANSYS was used to obtain the removal volume in a single-pulse discharge, and the electrode feed strategy, material removal, and renewal strategy are considered to establish the shape simulation strategy. Then, a program based on MATLAB software was compiled to simulate the machining process and predict the shape change of the multimaterial electrode of different combinations. The experiments of different multimaterial electrodes were carried out with the die steel as the workpiece. The simulation results were compared with the experimental results to verify the effectiveness of the simulation model.

Internet-Based Physical Simulation of Drilling Process

2004 ◽  
Vol 471-472 ◽  
pp. 552-556
Author(s):  
Li Hua Dong ◽  
Yan Ling Zhao ◽  
C.H. Fan
Keyword(s):  
Process Simulation ◽  
Network Architecture ◽  
Physical Simulation ◽  
Drilling Process ◽  
Machining Parameters ◽  
Drilling Force ◽  
Architecture Model ◽  
Simulation Results ◽  
Experimental Mathematic ◽  
Client Side

This paper presents the implementation of an internet-based facility for the drilling process simulation, which complies with TCP/IP and is supported by Browser/Server model. The process simulation is one of pivotal technologies and implemental techniques of the internet-based agility manufacturing technology. A network architecture model is developed with the WebServer toolbox of MatLab. The complicated drilling process is studied. Semi-experimental mathematic models of drilling force and torque are established. Users input different machining parameters in client-side and then they will get the simulation curves of cutting forces and torques and can evaluate the simulation results. At last, optimum machining parameters can be chosen by users via internet.

scholarly journals An Investigation on High-Resolution Temperature Measurement in Precision Fly-Cutting

Sensors ◽  
2021 ◽  
Vol 21 (4) ◽  
pp. 1530
Author(s):  
Daniel Gräbner ◽  
Tjarden Zielinski ◽  
Andrey Vovk ◽  
Oltmann Riemer ◽  
Bernhard Karpuschewski ◽  
...  
Keyword(s):  
Measurement Data ◽  
Machining Process ◽  
Machining Parameters ◽  
Good Match ◽  
Machining Processes ◽  
Machining Process Simulation ◽  
Fly Cutting ◽  
Advanced Machining ◽  
Simulation Results ◽  
Modification Of The Surface

The loads acting on a workpiece during machining processes determine the modification of the surface of the final workpiece and, thus, its functional properties. In this work, a method that uses thermocouples to measure the temperature in precision fly-cutting machining with high spatial and temporal resolution is presented. Experiments were conducted for various materials and machining parameters. We compare experimental measurement data with results from modern and advanced machining process simulation and find a good match between experimental and simulation results. Therefore, the simulation is validated by experimental data and can be used to calculate realistic internal loads of machining processes.

Electrode Classification and Retrieval Using Supported Vector Machine

2010 ◽  
Vol 160-162 ◽  
pp. 743-749
Author(s):  
Hua Chang Wang ◽  
Zhu Qing Lv ◽  
Zhi Gang Li
Keyword(s):  
High Efficiency ◽  
Promising Result ◽  
Automatic Classification ◽  
Cnc Machining ◽  
Machining Process ◽  
Svm Model ◽  
Cnc Programming ◽  
Surface Moment ◽  
Programming Process ◽  
Polar Radius

Due to the similarities between electrode model and their CNC machining process, process design could be finished efficiently using the electrode automatic classification system as well as the existed standard process template. This study developed an automatic classification retrieval system of electrode model by applying a statistical approach, namely SVM model, to the classification of electrode model, where 3D Polar-Radius Surface Moment was used to extract the feature vector of the electrode model. Experiments showed a promising result with an average classification accuracy up to 85.72% in addition to the high efficiency and usability. Most important, the developed approach is capable of reusing existing knowledge and experience and as a result it makes the CNC programming process easier.

Study on Numerical Control Machining Technology of Full-Surface Part

2012 ◽  
Vol 510 ◽  
pp. 384-389
Author(s):  
Jin Gui Wan ◽  
Fei Zhang ◽  
Bei Hua Li ◽  
Qi Gao
Keyword(s):  
Process Analysis ◽  
Nc Machining ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Parameters ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Numerical Control Machining ◽  
Surface Part ◽  
Nc Code

A complex part, which has curved surface overall, is trial-manufactured with CNC machine. The NC machining process and technology of this full-surface part are studied in this paper. First, the 3D model of the part is created in the modeling module of UG system. Then, process analysis and scheme are developed. As the part has an irregular shape and the entire surface is to be NC machined, there are many difficulties during processing. The optimized process plan is determined. In the manufacturing module of UG system, the NC machining parameters are set according to the processing requirements, the tool paths are generated, edited and checked, and the NC code is generated by post processing. Finally, the part is manufactured using a 3-axis CNC milling machine with the NC programs. It has desirable shape and high accuracy. The result shows that the NC process is reasonable and efficient. CAD/CAM integration technology is applied successfully in this example. The methodology and technology introduced in this paper can provide valuable reference for processing similar parts, and it is also useful for correlational study.

Modeling of Five-Axis Linkage WEDM for Complex Curved Surface and its Simulation

2012 ◽  
Vol 605-607 ◽  
pp. 1423-1426
Author(s):  
Xin Rong Wang ◽  
Ping Wang ◽  
Ya Chao Cui ◽  
Tao Han
Keyword(s):  
Computer Simulation ◽  
Mathematical Models ◽  
Ruled Surface ◽  
Machining Process ◽  
New Method ◽  
Curved Surface ◽  
Machining Parameters ◽  
Simulation Results ◽  
Five Axis ◽  
The Ideal

For the purpose of studying on the machining process of complex ruled surface, a new method of computer simulation about five-axis linkage WEDM was put forward.Through analyzing the characteristics of five-axis linkage WEDM and its motion laws, the related mathematical models were built. The whole machining process of five-axis linkage WEDM can be directly observed by running the simulation program. The ideal simulation results can be obtained. The ideal machining parameters gotten by computer simulation provide a theory basis for machining complicated ruled surface. Consequently, the machining capability of WEDM is extended and the problem of machining complicated ruled surface is resolved.

An Accurate and Efficient Approach to Three-Dimensional Geometric Modeling of Undeformed Chips for the Geometric and the Physical Simulations of Three-Axis Milling of Complex Parts

2015 ◽  
Vol 138 (5) ◽  
Author(s):  
Zhiyong Chang ◽  
Zezhong C. Chen
Keyword(s):  
Geometric Modeling ◽  
High Performance ◽  
Physical Simulation ◽  
Three Dimensional ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Parameters ◽  
Cnc Milling ◽  
Physical Simulations ◽  
Complex Parts

To pursue high-performance computer numerical control (CNC) milling of complex parts, it is crucial to simulate their machining process geometrically and physically with high fidelity beforehand. The geometric simulation is to construct three-dimensional (3D) models of the finished parts and to compute geometric deviation between the models and the part designs, in order to verify the planned tool paths. The physical simulation is to build undeformed chips geometric models and in-process workpiece models and to compute instantaneous cutting forces, in order to optimize the machining parameters. Therefore, it is essential to accurately and efficiently model undeformed chips geometry in machining complex geometric parts. Unfortunately, this work is quite challenging, and no well-established method for this work is available. To address this problem, our work proposes an accurate and effective approach to 3D geometric modeling of undeformed chips geometry in three-axis milling of complex parts. The outstanding feature of this approach is that undeformed chip models and in-process workpiece models can be effectively constructed. This approach lays a theoretical foundation for the geometric and the physical simulations of three-axis milling. It advances the technique of machining simulation and promotes high-performance machining of complex parts.

Dry machining of Inconel 718 super alloys using uncoated tool: Experimental and numerical analysis

2020 ◽  
Vol 108 (4) ◽  
pp. 402
Author(s):  
Merugu Rakesh ◽  
Saurav Datta
Keyword(s):  
Inconel 718 ◽  
Tool Material ◽  
High Strength ◽  
Experimental Tests ◽  
Contact Length ◽  
Machining Process ◽  
Machining Parameters ◽  
Precise Control ◽  
Adequate Understanding ◽  
Simulation Results

Aerospace super alloy Inconel 718 is difficult to process through conventional machining operation. Alloys with high strength at high temperatures and high strain hardening, high chemical affinity (towards tool material, and Co binder) etc. impose adverse effects towards smooth machining. Poor thermal conductivity of Inconel 718 promotes excessive temperature rise at the chip-tool interface which causes rapid tool wear, and degraded surface integrity of the end product. Adequate understanding of machining process phenomena along with precise control of machining parameters may yield satisfactory result. Trial, and error experimentation is indeed uneconomical; hence, in the present reporting, Finite Element (FE) based numerical simulation is attempted to model machining responses in the extent of cutting force, tool-tip temperature, depth of flank wear progression, chip-tool contact length, and finally, chip reduction coefficient. Simulation results are verified through experimental tests. Simulation results are found in good agreement with experimental results. Therefore, simulation results can reliably be used as an alternative instead of actual experimental effort.

A New High-Efficiency Error Compensation System for CNC Multi-Axis Machine Tools

2004 ◽  
Author(s):  
Shih-Ming Wang ◽  
Han-Jen Yu ◽  
Hung-Wei Liao
Keyword(s):  
Error Compensation ◽  
High Efficiency ◽  
Prediction Method ◽  
Compensation System ◽  
Machining Process ◽  
Error Prediction ◽  
Nc Code ◽  
Position Errors ◽  
Free Theory ◽  
Element Free

To enhance the accuracy of CNC machines for the request of modern industry, an effective static/quasi-static error compensation system composing of an element-free interpolation algorithm based on the Galerkin method for error prediction, a recursive software compensation procedure, and an NC-code converting software, is developed. Through automatically analyzing the machining path, the new error prediction method taking into the consideration of the fact that machine structure is non-rigid, can efficiently on-line determine the position errors of the cutter for compensation without computing a complex error model. The predicted errors are then compensated based on a recursive compensation algorithm. Finally, a compensated NC program will be automatically generated by the NC-code converting software for the precision machining process. Because of the advantage of element-free theory, the error prediction method can flexibly and irregularly distributing nodal points for accurate error prediction for a machine with complex error distribution characteristics throughout the workspace. To verify the algorithm and the developed system, cutting experiments were conducted in this study, and the results have shown the success of the proposed error compensation system.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

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