CAM Software Packages Research Articles

Integrating Trajectory Planning with Kinematic Analysis and Joint Torques Estimation for an Industrial Robot Used in Incremental Forming Operations

Robot manufacturing involves continuous path control, which is now available for both robotic controllers and CAM software packages. However, CAM solutions are focused on generating the code for the robotic structure to follow the toolpath, without taking into consideration the dynamics and energy consumption. In this study, robot incremental forming was considered as the manufacturing process, and a simulation model, based upon Matlab-Simulink Simscape Multibody technology, was developed. The proposed model was fed with the trajectory information generated by the CAM program, and using an inverse kinematics function, it was able to generate the commands to drive the robotic structure on the technological toolpaths. The model was also used to study the dynamic behavior of the robot; external experimental data from a 3D force sensor were fed to the model to include the influence of the technological forces which appeared during the incremental forming process. Thus, using the proposed model in conjunction with the external CAM software, the influence of the workpiece position upon the joint torques could be estimated, opening the way for future optimization. The shortcomings of the model, mainly involving inaccurate information with regard to the physical properties of the robotic structure, were addressed by subtracting the dry-run joint torques from those obtained from the technological process.

Study on the application of CAM techniques on CNC lathes with Y axis and driven tools

CNC lathes with Y axes and driven tools are machine-tools with complex kinematic. Using CAM techniques to program these machines is a cumbersome process and could easily lead to collisions. Collisions may occur not only between tools and workpiece but also between the mobile elements of the CNC lathe. While CAM software package can identify the first type of collisions, for the second type supplementary measures must be taken. This work presents the build of a kinematic model of such a CNC lathe and how can the CAM techniques be improved by using this model.

Using open source software CNC controllers and modular multi-axis mechanical structure as integrated teaching environment for CAD/CAM/CAE training

Open source CNC controllers, such as Linux CNC are used more and more because they are open source projects and consequently are available for free. Moreover, these controllers are highly customizable, and their capabilities are close to the commercial solutions. The paper presents how using Linux CNC controller and a modular structure of a multi-axis CNC machine-tools, built by a commercial company, an integrated environment for training students in implementing CAM techniques was developed. Aside the CNC controller and the machine-tool, a CAM software package was used for programming complex machining operations. The kinematic model of the machine was built, for the user to be able to simulate, in a realistic way the multi-axes machining operations. The integrated teaching environment enable the users to be trained in CNC programming for three to five axes machining operations. Advanced programming strategies, such as tool center point management (TCPM) can also be tested.

Design and technological support for manufacturing a PAA emitter based on a 3D-model using SolidWorks CAD

This article presents a methodology for manufacturing the S-band phased antenna array (PAA) emitter based on a calculated 3D-model, which provides the necessary design and technological requirements. As a method of manufacturing the emitter, the technology of milling processing on a CNC machine was chosen. Verification of milling processes based on the SolidWorks CAM software package was performed.

Fabrication of Edge Rounded Polylactic Acid Biomedical Stents by the Multi-Axis Micro-Milling Process

This paper presents the first try to fabricate degradable polylactic acid (PLA) biomedical stents with round edges by the multi-axis micro-milling process. Conventionally biomedical stents are produced by laser processing. Post-processing operations are usually required to handle sharp edges and thermal defects of the stent due to laser processing. A computer graphics software package was used to design the strut structures with round corners of the PLA stent. A PLA tube was first created using injection molding, and a degradable biomedical stent was then fabricated through micro-milling by using a five-axis computer numerical control (CNC) machine tool. This study investigated the error in the rotation center that can occur during five-axis micro-milling. Data obtained from experiments on center-of-rotation errors were substituted into homogeneous coordinate conversion formulas. Center-of-rotation errors in the five-axis machine tool were compensated for improving the milling precision (A and C axes) to be within 5 μ m. Furthermore, milling parameter optimization experiments were conducted, which determined the optimal conditions for milling PLA to be a spindle speed of 60,000 rpm, feed per tooth of 0.005 mm, and feed rate of 600 mm/min, and achieved the minimum burr 0.01 mm and the average surface roughness (Ra) 0.4 μ m. These optimal cutting parameters will be used in the following actual stent processing experiments. Finally, the error compensation and optimal parameters were combined in a CAM software package and layered spiral micromilling to machine the actual stent. The experimental results revealed that the combination of five-axis micro-milling led to the successful fabrication of a degradable biomedical stent (stent diameter = 6 mm, strut width = 0.3 mm, and radius at round corners = 0.1 mm). The machined actual stent had cross-section height and width errors within 0.01 mm, and arc depth of cut variation within 6 μ m. In addition, the PLA stent machining results indicated a rebound of approximately 33% at the strut round edge machining. This work may also open up future possibilities for complex three-dimensionally structured biomedical stents for better performance and special functionality.

Simulated 3-axis versus 5-axis Processing Toolpaths for Single Point Incremental Forming

Accuracy and productivity of the parts manufactured by single point incremental forming (SPIF) are influenced by the proper selection of toolpaths. CAM software packages are often used for generating the toolpaths for the process. Literature survey have revealed that contour curves and spatial spirals are the most used toolpaths for SPIF. These toolpaths are generated using 3-axis approaches, meaning that the tool axis is maintained parallel to the vertical axis. The 3-axis approach was justified using 3-axis CNC milling machines as the main technological equipment for SPIF. However, nowadays, the wide spreading of both 5-axis CNC milling machines and industrial robots, with far superior kinematic capabilities justifies the research of more complex toolpaths for unfolding SPIF. In this paper, 5-axis toolpaths, where the tool is oriented by normal to machining surfaces are proposed and compared with 3-axis toolpaths, by means of simulation.

Reason Maintenance in Product Modelling via Open Source CAD System

The present and future challenges of a new product design, forecasting and risk management launch strategy for a new product modelling decision process. This paper intends to propose and to look towards the development of a low-cost integrated CAD-CAPP-CAD/CAM product modelling system for the design and manufacture of a proposed product. It is a mapping between several design phases like functional design, technical design and physical design. The modelling data generation process begins with the drafting of a product to be maintained using the drafting software package. From the CAD drawing, the data are transferred to be used as the product models and a CAPP software package will then prepare the operational parameters for the manufacturing of the product. These process data are relayed to a CAM software package, which will then generate the automating information-processing functions. The final stage of the function is to support design and manufacturing operations that may have reaped many benefits in terms of its initial equipment and software costs.

Methodology of selecting CAM software package for education based on a questionnaire

Selecting computer-aided manufacturing software that meets learners’ requirements in education is a difficult process. Selection of a wrong software package can turn out to be costly in terms of allocated learning time and adaptability of students to software packages used in industries. This paper presents a methodology to provide selection criteria in education based on the theoretical model of activity theory. The main identified factors allowed us to draw up a questionnaire. This questionnaire aimed at getting learning effectiveness consideration from a group of 50 students of higher education using computer-aided manufacturing software. The processing and analysis of the questionnaire data helped us to set general criteria for the selection of computer-aided manufacturing software to be used for education purposes.

Optoelectronic Method for Monitoring the State of the Cryolite Melt in Aluminum Electrolyzers

The surface state of the cryolite–alumina melt of the aluminum electrolyzer is investigated using an acA640-120gc industrial color camera (Basler, Germany) and developed AMS CAM (automated measurement system for cryolite–alumina melt) software package. The dependence of varying the total brightness at various alumina concentrations is found. The growth rate is determined and features of formation of a crust on the melt surface with various cryolite ratios are revealed.

Feedrate optimisation/scheduling on sculptured surface machining: a comprehensive review, applications and future directions

Free-form or sculptured surface milling is one of the continually used manufacturing processes for die/mould, aerospace (especially turbine blades), precision machine design, bio-medical devices and automotive industries. Developments of machining technologies for quality enhancement of machining results have become a very important fact in current real industry. Therefore, reducing milling time, tool wear, cutter deflection and improving surface texture quality and machining operations through adaptation and optimisation of tool feedrates based on changing surface geometry in sculptured surface machining is a great step in this direction. Various feedrate optimisation strategies have different feedrate rescheduling control parameters such as chip thickness, material removal rate (MRR), min(mrr,chip,force), max(expo.Acc/dec) and resultant forces. Some commercial CAM softwares come with MRR-based feedrate optimisation algorithms which have a very short calculation time. However, commercial feedrate scheduling systems have some limitations in generating the scheduled feedrates because they use the MRR or the cutting force model which is dependent on milling conditions. However, for the processes in which machining precision/accuracy is very important, it is inevitable that mechanistic force-based feedrate optimisation approaches, for which the calculation time is improved, will be integrated into commercial CAM software packages. Here, developing only the mechanistic cutting force-based algorithm is not enough. In this paper, improvement and optimisation of machining feedrate value, which is one of the cutting parameters which has a tremendous effect on the precise machining of free-form surfaces, was discussed by using the virtual machining framework. For this purpose, the boundary representation solid modelling technique-based free-form milling simulation and feedrate optimisation system integrated with commercial CAD/CAM software is developed for three-axis ball-end milling. This review study includes the information regarding the following topics: The algorithms developed for the feedrate value optimisation, MRR calculation approaches, cutting force computation methods, details of algorithms, the effects on the surface accuracy, the effects on the machining time, the capabilities of the present commercial CAM software packages, the encountered difficulties and overcoming those difficulties, recent developments and future research directions.

Integrating CAD/CAM software for process planning applications

The selection of machining parameters is an important process planning function for manufacturing processes. Typically, machining parameter selection is done manually; although, some software packages are available to assist the process planner with this function. This paper describes a method for integrating commercial CAD and CAM software packages to provide a process planning tool that can substantially increase productivity and reduce lead-time. The proposed method is based on the concepts of wrappers and neutral data formats. An implementation example is presented to demonstrate the method and the potential for on-line machining parameter selection in an integrated CAD/CAM environment.

Optimisation of tool path geometry for efficient machining

In this paper, different tool paths related to CNC-based turning operations for complex irregular geometry have been investigated and time efficient tool paths which can lead to optimisation of tool paths have been proposed. Kinematic and graphical models were used to study conventional axial and contour parallel tool path geometris to predict the time efficient tool path geometry. Given that the optimum machining conditions are available in CAM software packages or CNC machine controllers [1], the proposed consideration of the tool path geometry will further improve the production rate by reducing the machining time following the reduced tool path contour lengths for the same amount of material removal and similar machining conditions.

An integrated intelligent process planning system for prismatic parts using PC-based CAD and CAM software packages

Traditional machining process planning relies heavily on human decision making and manual calculations. The utilisation of CAM software and computers to aid machining reduces errors and planning time. A fully integrated planning system using CAD and CAM software would further increase the efficiency of process planning. The goal of this research is the automation of machining process planning for prismatic parts by integrating Autocad and Mastercam software packages using the Autolisp programming language and artificial intelligence techniques. Using only a 3D representation of the prismatic part geometry drawn in Autocad as input, the integrated system will be capable of producing NC code for the machining of the part with minimal human intervention. This system would greatly enhance the productivity of machining process planning.

Development of an integrated CAD/CAPP/CAM system for turning operations

Automating information-processing functions to support design and production operations may have reaped many benefits but this can also be an expensive affair in terms of its initial equipment and software costs. This paper looks at the development of a low-cost integrated CAD/CAPP/ CAM (IDPM) system for the design and manufacture of turned components. The automated information generation process begins with the draughting of a part to be turned using the drafting package Auto CAD. From the CAD drawing, the data are transferred to coroplan, a CAPP software package, which will then prepare the operational parameters and the machining sequence and assign the tasks to the appropriate work centres for the producing of a turned component. These process data are relayed to SmartCAM, a CAM software package, which will then generate the necessary numerical machine codes for the machining of a turned part. Preliminary work on the machining of a turned product with complex features using the IDPM system has been found to be promising and satisfactory. The absolute average size tolerance of the turned product is found to be 0.055 mm.

Development of an integrated CAD/CAPP/CAM system for turning operations

Automating information-processing functions to support design and production operations may have reaped many benefits but this can also be an expensive affair in terms of its initial equipment and software costs. This paper looks at the development of a low-cost integrated CAD/CAPP/ CAM (IDPM) system for the design and manufacture of turned components. The automated information generation process begins with the draughting of a part to be turned using the drafting package Auto CAD. From the CAD drawing, the data are transferred to coroplan, a CAPP software package, which will then prepare the operational parameters and the machining sequence and assign the tasks to the appropriate work centres for the producing of a turned component. These process data are relayed to SmartCAM, a CAM software package, which will then generate the necessary numerical machine codes for the machining of a turned part. Preliminary work on the machining of a turned product with complex features using the IDPM system has been found to be promising and satisfactory. The absolute average size tolerance of the turned product is found to be 0.055 mm.