Minimizing the Energy Consumption of Holes Machining Integrating the Optimization of Tool Path and Cutting Parameters on CNC Machines

The application of sustainable manufacturing technologies is the new challenge faced by enterprises, industries, and researchers under the background of supporting carbon peak and carbon neutral. This paper studies how to reduce the energy consumption of holes machining through optimizing tool path and cutting parameters simultaneously. The integrated optimization methodology can further reduce the energy consumption comparing with optimizing the tool path or cutting parameters separately. Firstly, the energy model of holes machining is established based on machine tools’ energy composition, tool path planning, and process parameters. Due to tool path planning as air cutting process has big relationship with reducing energy, especially for holes group with a big proportion in the whole process. The tool path of holes processing is optimized by the improved ant colony algorithm to solve the issue considering the distance from one hole to the next hole. Based on this optimized path, a multi-objective optimization model for hole cutting parameters is established, considering the spindle speed and feed rate as the optimization variables and machining time, energy consumption, and surface roughness as the objective function. The non-dominated sorting genetic algorithm (NSGA-Ⅱ) is employed to solve the multi-objective optimization problem of holes machining. The case study with 50 holes is used to testify the application of the proposed method to provide the practical energy efficiency strategy for holes group or multi-hole parts on CNC machines assisting in achieving sustainable production in manufacturing sectors.

A Tool-path Planning Method Used in Computer Controlled Optical Surfacing Based on Improved Prim Algorithm

In view of the disadvantages of existing planning methods used in CCOS techniques, such as low efficiency and workpieces contain obvious mid-frequency error after polishing, a new tool-path planning method based on improved Prim algorithm was proposed, of which the core idea was consist by following steps: surface data reading, mesh generation, distribution of resident points determining and polishing path generating. After that, comparison of raster path and the path based on improved Prim algorithm was carried out by simulated experiments from aspects of path length and polishing texture. The results indicated that the path based on improved Prim algorithm could shorten path length as well as increase polishing efficiency, moreover, both the texture and mid-frequency errors can be improved by using the path presented. It was concluded that the presented planning method could improve polishing efficiency and machining quality. Then, comparison between raster path and the path based on improved Prim algorithm was carried out by simulated experiments, from two sides of path length and polishing texture. The results indicated that the path based on improved Prim algorithm could shorten path length as well as increase polishing efficiency, moreover, both the texture and mid-frequency errors would be improved by using the presented path. Finally, the validity of presented planning method was proved in machining experiments.

Coverage Based Tool-Path Planning For Automated Polishing Using Contact Mechanics Theory

Presented in this thesis is a method for tool-path planning for automated polishing. This work is an intergral part of the research program on automated polishing/deburring being carried out at Ryerson University. Whereas tool-path planning for machining is treated as a geometry problem, it ks shown here that tool-path planning for polishing should be treated as a contact mechanics problem because of the contact action between the polishing tool and the part surface. To develop this algorithm, contact mechanics is applied for contact area modeling and analysis, Once the contact area is determined, for multiple contact points along the given polishing path, a map of the contact area is generated and utilized to show the coverage area during polishing. This map is then used to plan a polishing path that ensures complete coverage for polishing, Simulation has been carried out to show the effetiveness of this new polishing path algorithm.

Coverage Based Tool-Path Planning For Automated Polishing Using Contact Mechanics Theory

Presented in this thesis is a method for tool-path planning for automated polishing. This work is an intergral part of the research program on automated polishing/deburring being carried out at Ryerson University. Whereas tool-path planning for machining is treated as a geometry problem, it ks shown here that tool-path planning for polishing should be treated as a contact mechanics problem because of the contact action between the polishing tool and the part surface. To develop this algorithm, contact mechanics is applied for contact area modeling and analysis, Once the contact area is determined, for multiple contact points along the given polishing path, a map of the contact area is generated and utilized to show the coverage area during polishing. This map is then used to plan a polishing path that ensures complete coverage for polishing, Simulation has been carried out to show the effetiveness of this new polishing path algorithm.