Optimization of the Process Parameters for Micro-Milling Thin-Walled Micro Parts Using Advanced Algorithms

The surface integrity and machining accuracy of thin-walled micro parts are significantly affected by micro-milling parameters mostly because of their weak stiffness. Furthermore, there is still a lack of studies focusing on parameters optimization for the fabrication of thin-walled microscale parts. In this paper, an innovative approach is proposed for the optimization of machining parameters with the objectives of surface quality and dimension accuracy, which integrates the Taguchi method, principal component analysis method (PCA) and the Non-dominated sorting genetic algorithm (NSGA-II). In the study, surface arithmetic average height Sa, surface root mean square height Sq, and 3-D fractal dimension Ds are selected to evaluate surface quality. Then micro-milling experiments are conducted based on the Taguchi method. According to the experimental results, the significance of machining parameters can be determined by range analysis. Besides, regression models for the responses are developed comparatively, and the PCA method is employed for dimension reduction of the optimization objective space. Finally, two combinations of machining parameters with the highest satisfaction are obtained through NSGA-II, and verification experiments are carried out. The results show that the surface quality and dimension accuracy of the thin-walled microscale parts can be simultaneously improved by using the proposed approach.

Multi-Stage Prediction of Feed System Time Series

In order to reduce the tracking error of the computer numerical control (CNC) feed system and improve the CNC machining accuracy, a novel prediction model is proposed based on fuzzy C-means robust variational echo state network. Firstly, the feed speed time series is clustered, and then reconstructed for different categories. The multi-stage robust prediction models are established to realize the multi-state robust prediction of the CNC machining feed velocity to reduce the tracking error of the feed system. Finally, the reference and actual time series with different feed speed are used to verify the established models. The results show that the proposed method can reduce the tracking error and realize the effective prediction of the time series of the feed system.

Research on the integrated manipulator of point cloud measurement and precise cutting for waste nuclear tank

Purpose Nuclear waste tanks need to be cut into pieces before they can be safely disposed of, but the cutting process produces a large amount of aerosols with radiation, which is very harmful to the health of the operator. The purpose of this paper is to establish an intelligent strategy for an integrated robot designed for measurement and cutting, which can accurately identify and cut unknown nuclear waste tanks and realize autonomous precise processing. Design/methodology/approach A robot system integrating point cloud measurement and plasma cutting is designed in this paper. First, accurate calibration methods for the robot, tool and hand-eye system are established. Second, for eliminating the extremely scattered point cloud caused by metal surface refraction, an omnidirectional octree data structure with 26 vectors is proposed to extract the point cloud model more accurately. Then, a minimum bounding box is calculated for limiting the local area to be cut, the local three-dimensional shape of the nuclear tank is fitted within the bounding box, in which the cutting trajectories and normal vectors are planned accurately. Findings The cutting precision is verified by changing the tool into a dial indicator in the simulation and the experiment process. The octree data structure with omnidirectional pointing vectors can effectively improve the filtering accuracy of the scattered point cloud. The point cloud filter algorithm combined with the structure calibration methods for the integrated measurement and processing system can ensure the final machining accuracy of the robot. Originality/value Aiming at the problems of large measurement noise interference, complex transformations between coordinate systems and difficult accuracy guarantee, this paper proposes structure calibration, point cloud filtering and point cloud-based planning algorithm, which can greatly improve the reliability and accuracy of the system. Simulation and experiment verify the final cutting accuracy of the whole system.

Reliability Evaluation of CNC Machine Tools Considering Competing Failures of Fault Failure Data and Machining Accuracy Degradation Data

Traditional reliability evaluation of CNC machine tools usually considers a single failure mode of fault failure or degradation failure, or considers fault failure and degradation failure to be independent of each other. However, in the actual working conditions, fault failure and degradation failure are mutually affected, and the reliability evaluation of the competing failure models of CNC machine tools by considering the two failure modes comprehensively can get more accurate evaluation results. Therefore, this paper proposes a reliability evaluation method for CNC machine tools considering fault failure data competing with machining accuracy degradation data. A fault failure model of CNC machine tools is established based on a non-homogeneous Poisson process. The fault failure model is updated according to the different effects of each maintenance result of the failure on machining accuracy. By integrating multiple geometric errors of CNC machine tools through multi-body system theory, the amount of machining accuracy degradation is extracted. A machining accuracy degradation failure model is established using the Wiener process. Considering the correlation between fault failure and degradation failure, a competing failure model based on the Coupla function is developed for evaluating the reliability of CNC machine tools. Finally, the effectiveness of the proposed method is verified by example analysis.

Improving Machining Accuracy for a Robotic Arm with Hybrid Kinematic Chains Based on Deformation Characteristics

The joint deformation has great influence on machining accuracy for a robotic arm. In this paper, the deformation characteristics of the robotic arm with hybrid kinematic chains is investigated in order to improve its machining accuracy. Firstly, the deformation model of the joints has been established based on the Strain energy method and Castigliano theorem according to the robot structure. Secondly, the deformation influence coefficient (DIC) is defined to investigate the deformation influence of main components on the end-effector, and the deformation characteristics are evaluated by the simulation. Finally, a small size robotic arm prototype is established and robotic drilling comparative experiments are conducted. The theoretical and experiment results show that the machining method can be selected according to the DIC, which the force can be applied to the components with better stiffness. On the other hand, the deformation of driving components can also be reduced when the DIC cannot be adjusted to meet the accuracy requirement.

Mechanism of Blunt Punching Tools’ Influence on Deformation and Residual Stress Distribution

Punching is the main manufacturing process with high efficiency and machining accuracy used to produce the iron cores of motors. However, it usually introduces residual stress at the cutting edge and affects the magnetic properties of the iron core. Further studies show that the tensile residual stress (TRS) has a negligible effect on the magnetic properties, compared with the compressive stress. The blunt punch tools cause local TRS and the formation of local large plastic deformation (PD) at the cutting edge as the cost. The PD has a more serious effect on the magnetic properties of materials than TRS. Therefore, this study mainly focused on local deformation distribution and the associated microstructure evolution using EBSD (Electron Backscatter Diffraction) and finite element analysis; and the formation mechanism of tensile residual stress during the punching process at the cutting edge of a non-oriented silicon steel after punching with blunt tools, by using nanoindentation and a numerical simulation. The experimental results showed the existence of a specific bending area, a highly deformed area and a large burr at the cutting edge. These direct observations were confirmed with those obtained by the simulation model. Furthermore, the tensile residual stress on the surface was verified through nanoindentation tests and by a numerical simulation. The results indicate also that the formation of a tensile residual stress zone depends especially on the bending area formed during punching with blunt tools.

Fabrication of Microgrooves by Synchronous Hybrid Laser and Shaped Tube Electrochemical Milling

The fabrication of deep microgrooves has become an issue that needs to be addressed with the introduction of difficult-to-cut materials and ever-increasing stringent quality requirements. However, both laser machining and electrochemical machining could not fulfill the requirements of high machining efficiency and precision with good surface quality. In this paper, laser and shaped tube electrochemical milling (Laser-STEM) were initially employed to fabricate microgrooves. The mechanisms of the Laser-STEM process were studied theoretically and experimentally. With the developed experimental setup, the influences of laser power and voltage on the width, depth and bottom surface roughness of the fabricated microgrooves were studied. Results have shown a laser power of less than 6 W could enhance the electrochemical machining rate without forming a deep kerf at the bottom during Laser-STEM. The machining accuracy or localization of electrochemicals could be improved with laser assistance, whilst the laser with a high-power density would deteriorate the surface roughness of the bottom machining area. Experimental results have proved that both the machining efficiency and the machining precision can be enhanced by synchronous laser-assisted STEM, compared with that of pure electrochemical milling. The machining side gap was decreased by 62.5% while using a laser power of 6 W in Laser-STEM. The laser-assistance effects were beneficial to reduce the surface roughness of the microgrooves machined by Laser-STEM, with the proper voltage. A laser power of 3 W was preferred to obtain the smallest surface roughness value. Additionally, the machining efficiency of layer-by-layer Laser-STEM can be improved utilizing a constant layer thickness (CLT) mode, while fabricating microgrooves with a high aspect ratio. Finally, microgrooves with a width of 1.79 mm, a depth of 6.49 mm and a surface roughness of 2.5 μm were successfully fabricated.

Full-factor matrix model of accuracy of dimensions performed on multi-purpose CNC machines

Introduction. One of the main reasons that modern multi-purpose CNC machines do not use the capabilities of multi-tool processing is the lack of recommendations for design in this direction and, accordingly, for adjustment schemes. The study of the possibilities of multi-tool processing on multi-purpose machines is the subject of the work. The purpose of research: The problem of developing full-factor matrix models of dimensional accuracy and its sensitivity to the machining process is considered to increase the machining efficiency while ensuring machining accuracy using the technological capabilities of multi-tool machining on modern multi-purpose CNC machines. For this purpose, full-factor matrix models of the size scattering fields performed on multi-tool double-carriage adjustments have been developed, taking into account the cases of processing parts with dimensions that differ sharply in different directions, which are often encountered in practice, and in this case, the significant influence of the turns of the workpiece on the processing error, especially in directions with sharply different overall dimensions. Results of research: The developed accuracy models make it possible to calculate not only plane-parallel displacements of the technological system for double-carriage adjustments, but also angular displacements around base points, take into account the combined effect of many factors – a complex characteristic of the subsystems of the technological system (plane-parallel matrix of compliance and angular matrix of compliance), the geometry of the cutting tool , the amount of bluntness of the tool, cutting conditions, etc. As a result, based on the developed accuracy models, it is possible to obtain several ways to control multi-tool machining, including improving the structure of multi-tool adjustments, calculating the limiting values of cutting conditions. Based on the developed full-factor matrix models, it became possible to develop recommendations for the design of adjustments and the creation of an automated design system for multi-tool machining for a group of modern multi-purpose CNC lathes. Scope of the results: The results obtained can be used to create mathematical support for the design of operations in CAD-systems provided for multi-tool multi-carriage machining performed on multi-purpose machines. Conclusions: The developed models and methodology for simulating the machining accuracy make it possible to increase the accuracy and efficiency of simultaneous machining, to predict the machining accuracy within the specified conditions.

Suppression of Thrust Fluctuation of a New Ironless Tubular Permanent Magnet Synchronous Linear Motor Based on the Halbach Array

The air gap magnetic field (AGMF) is the key factor in determining the ironless tubular permanent magnet synchronous linear motor (ITPMSLM). The distortion of its waveform causes thrust fluctuation during the operation of the motor, resulting in poor machining accuracy of the machine tool. To solve this problem, this paper proposes a new chamfered permanent magnet structure (CPMS) to improve its performance. First, the equivalent magnetic charge method is used to analyze the AGMF, and the analytical expressions of the no-load back EMF and thrust of the new motor are obtained. Second, the AGMF of six kinds of CPMS is analyzed by the Fourier coefficient. Taking the minimum harmonic distortion rate as the optimization objective, the CPMS that makes the AGMF waveform reach the best sinusoidal property is obtained and the no-load back EMF and thrust of the new motor are analyzed. Then, the new motor is compared with the ITPMSLM of rectangle permanent magnet structures (RPMS). Finally, according to the CPMS, the test prototype is built and tested under different working conditions. The research results show that when the outer circumference is 45o chamfered, the ratio of permanent magnet thickness h2 to the chamfered thickness h1 is 0.8; the sinusoidal property of AGMF is the best, and this structure can effectively reduce the motor thrust fluctuation rates to less than 0.01%, which verifies the effectiveness of the CPMS in improving the sinusoidal property in the AGMF and restraining the thrust fluctuation of the ITPMLSM.