CAM Software Research Articles

Smart automation in luxury leather shoe polishing: a human centric robotic approach

ABSTRACT The polishing of luxury leather shoes is a delicate, labor-intensive process traditionally performed by skilled craftsmen. Footwear companies aim to automate parts of this process to enhance quality, productivity and operator well-being, but the unique nature of luxury shoe production presents challenges. This paper introduces a solution involving a collaborative robotic cell to assist in shoe polishing. A collaborative robotic manipulator, equipped with a specialized tool and governed by force control, executes the polishing tasks. Key factors such as trajectory design, applied force, polishing speed and polish amount were analyzed. Polishing trajectories are designed using CAM software and transferred to the robot’s control system. Human operators design the process, supervise the robot and perform final finishing, ensuring their expertise is integral to achieving quality. Extensive testing on various shoe models showed significant improvements in quality and reliability, leading to successful implementation on an industrial production line.

Integration of Metrology in Grinding and Polishing Processes for Rotationally Symmetrical Aspherical Surfaces with Optimized Material Removal Functions

Aspherical surfaces, with their varying curvature, minimize aberrations and enhance clarity, making them essential in optics, aerospace, medical devices, and telecommunications. However, manufacturing these surfaces is challenging because of systematic errors in CNC equipment, tool wear, measurement inaccuracies, and environmental disturbances. These issues necessitate precise error compensation to achieve the desired surface shape. Traditional methods for spherical optics are inadequate for aspherical components, making accurate surface shape error detection and compensation crucial. This study integrates advanced metrology with optimized material removal functions in the grinding and polishing processes. By combining numerical control technology, computer technology, and data analysis, we developed CAM software (version 1) tailored for aspherical surfaces. This software uses a compensation correction algorithm to process error data and generate NC programs for machining. Our approach automates and digitizes the grinding and polishing process, improving efficiency and surface accuracy. This advancement enables high-precision mass production of rotationally symmetrical aspherical optical components, addressing existing manufacturing challenges and enhancing optical system performance.

A Microscopy Evaluation of Emergence Profile Surfaces of Dental Custom CAD-CAM Implant Abutments and Dental Implant Stock Abutments.

Recently, due to the high demand for dental implants, the use of dental implant stock abutments has increased significantly, especially dental custom CAD/CAM implant abutments milled by dental technicians in their laboratories. The purpose of this study is to analyze the surface quality of the emergence profile of dental custom CAD/CAM implant abutments made by a non-industrial milling machine, compared to original and compatible dental implant stock abutments made by industrial machines. Thirty dental implant abutments were divided into six study lots. Lot 1 (control group): original dental implant stock abutments-industrial machined; lot 2 (study group): compatible dental implant stock abutments-industrial machined; lots 3, 4, 5, and 6 (study groups): compatible custom CAD/CAM dental implant abutments-non-industrial milled with hyperDENT CAM software and Paragon Tools. The Nikon SMZ745T stereomicroscope was used to analyze the emergence profile surface of each dental implant abutment. The structure of the analyzed surfaces did not show significant differences between original and compatible abutments that were industrially machined. As for the customized dental implant abutments, the greatest similarity with the original was obtained for lot 6, and a significant statistical difference was obtained for lot 4. Stepover and Feed Rate parameters of the milling process influenced the surface roughness of the emergence profile for the customized dental implant abutments. The digital technology of non-industrial milling compatible custom CAD/CAM dental implant abutments is reliable and within the correct milling parameters.

Hybrid FFF/CNC: An open source hardware & software system

This paper presents a low-cost milling system composed of spindle mountable on a multi tool 3D printer equipped with maxwell kinematic coupling (E3D “ToolChanger” in this article) as well as two open-source software solutions for implementing a hybrid FFF/CNC manufacturing process. The first solution is the use of a traditional CAM software (FreeCad) for machining programming through the development of a dedicated post-processor. The second is an automatic layer-by-layer hybridization enabled by the software “SuperSlicer”. This method requires no machining knowledge but only allows contouring operations. Results of experiments show that the spindle presented in this work is capable of successfully carrying out a hybrid process that significantly improves the surface roughness parameters, with an improvement factor of 10 for most parameters. An uniformization of surface roughness parameters was also observed in the construction direction and in the deposition/machining direction. The layer-by-layer hybridization yields the better results in terms of surface roughness. This is because the reduced depth of cut (equivalent to a printed layer) minimizes stress and temperature rise, resulting in highly favorable cutting conditions.

Flexural properties and fatigue limit of 3D-printed and milled resin-based materials.

The purpose of this study was to evaluate the flexural strength (FS), flexural modulus (FM), and fatigue limit (FL) of 3D-printed resin-based polymers and composites and compare them to 3D-printed composites. A bar-shaped specimen (25×2×2mm) was CAD designed according to ISO 4049:2019, and 60 duplicates of the 3D model were nested at a 45-degree angle with the printing platform and 3D-printed with three materials: denture teeth resin (Denture Teeth, Formlabs), temporary crown and bridge resin (Temporary CB, Formlabs), and composite (Flexcera Smile Ultra+, Desktop Health). The 3D model was also imported into a dental CAM software, duplicated 60 times, nested, and milled from a 3D-milled composite puck (Ivotion Denture Teeth, Ivoclar). All specimens were post-processed following the manufacturer's recommendation. The specimens were then subjected to a three-point bending test until failure using a Universal Testing Machine at a crosshead speed of 0.75mm/min, and FS and FM were calculated. The remaining thirty specimens were tested for Fatigue Limit using the staircase approach starting at 50% FS maximum up to 1.2M cycles at 10Hz. The data were analyzed using one-way ANOVA and the Weibull distribution (α = 0.05). The results showed that Ivotion and Flexcera had higher FS (110.3 ± 7.1MPa and 107.6 ± 6.4MPa, respectively) and FM (3.3 ± 0.1GPa and 3.0 ± 0.2GPa, respectively) compared to the 3D-printed Denture Teeth (FS = 66.4 ± 18.5MPa and FM = 1.8 ± 0.1GPa) and Temporary CB (FS = 79.6 ± 12.1MPa and FM = 2.7 ± 0.4GPa). Weibull analysis showed that the Ivotion and Flexcera had a more uniform and narrower spatial distribution of defects (m: 27.98 and 29.19) than the printed materials, which had m values of 8.17 and 4.11 for Temporary CB and Denture Teeth, respectively. Although no differences were found in the static properties (FS and FM) between Ivotion and Flexcera, Ivotion presented a higher endurance limit than Flexcera (51.43 vs. 40.95MPa). The Temporary CB presented 21.08MPa and Denture Teeth presented 17.80MPa of endurance limit. 3D-milled (Ivotion Denture Teeth) and 3D-printed (Flexcera Smile Ultra+) composites outperformed 3D-printed resins (Formlabs Denture Teeth and Temporary Crown & Bridge) in terms of flexural properties and fatigue resistance. 3D-milled (Ivotion) and 3D-printed (Flexcera) composites exhibited similar flexural properties, but 3D-milled composites showed a 25% higher fatigue endurance limit, suggesting improved clinical longevity.

LCA involving process planning

In the context of biological transformation, the goal in process planning is to support the user towards more efficient and especially more sustainable processes. A life cycle assessment (LCA) is a tool used to evaluate the environmental impact of a product or process over its entire life cycle. So far, the modelling of a milling process strongly depends on the removed volume. Information available from a state-of-the-art CAM software like tool path length, linking movements and retractions of the machine are neglected. Therefore, this paper methodically investigates the potential for process planning to include LCA models for milling operation to implement more sustainable manufacturing processes.

Analysis of Polyurethane Foam Machining Parameter Influence: Current Status and Perspective

Nowadays, polyurethane (PU) foam has successfully replaced various engineering materials in many applications due to its many advantages in mechanical and thermal properties. In various applications, PU foam must be formed into various 3-dimensional models according to user requirements by utilizing CAM software and CNC milling machining to manufacture a product. Thus, the selection of cutting parameters in the milling machining process in terms of the nature and character of the material and cutting tools is essential and significantly influences the geometric structure and surface roughness of the PU foam products produced. Based on the review of this article, several machining parameters must be appropriately considered, including spindle rotation speed, depth of cut, cutting tool selection, and feed rate. Vibration will increase as the spindle rotation speed increases, which brings cutting tools but results in better surface quality. Continuous chip formation can be achieved by selecting the proper cut depth and producing low surface roughness values. Selecting suitable cutting tools and geometries that match the material characteristics can reduce the risk of material damage during the machining process, thereby reducing the surface roughness value. Finally, a low cutting rate will minimize surface roughness but increase the risk of cutting-edge wear.

Research on Digital Manufacturing Technology of Key Components of Artificial Knee Joint

The surface of the artificial knee joint manufactured by 3D printing technology is rough. This study uses advanced multi-axis machining technology to study how to improve the manufacturing accuracy of the artificial knee joint surface, and uses five-axis machining CAM software to analyze the process of three-dimensional model of the artificial knee joint and to compile tool path, create a five-axis special post-processor, convert the tool path point file into the NC program for machine tool processing. In order to ensure the safety and efficiency of the processing procedure, a Mikron HEM-500U machine tool simulation platform was built in the VERICUT simulation system for simulation processing verification, and then the blank prototype obtained by 3D printing was processed in a five-axis machine tool to meet medical clinical use requirements.

Performance and analysis of sputtered silicon nitride cutting inserts in CNC machining

In this automated world, the role of machine tools such as cutting inserts and drills required for any type of work piece plays an important role in producing precision outputs. As technology improved, the manufacture of Components is mostly automatic in all type of manufacturing industries. The different measurements for a given component are generated with CAD software and then transformed into a finished component with CAM software. CNC machines are used in industries to cut metal components with extreme precision for any hardware goods. Automobile parts, aero parts and polymer consumer components are the most often produced things by these machines. Since these machines have certain specifications, CNC machines frequently use additional tools and parts which includes cutting inserts. So, in this automated environment, these cutting inserts quality has to be ensured for maintaining the precision measurements. A wide known fact is that insert tool failure occurs due to tool wear. When comparing with uncoated Silicon nitride insert, the working life span of coated insert can also be increased. Hence for this reason, DC magnetron technique is proposed to ensure quality and also to increase life of cutting tool by improving its hardness and wear resistance by coating a thin film of tungsten carbide in cutting tool insert. For this reason, the hardest material Tungsten carbide is coated over the Silicon Nitride tool insert. The coated insert has to be tested for its microstructure, surface hardness and grain distribution. Later, bonding efficiency and surface hardness test has to be carried out through Nano indentation and scratch test process.

Impeller Machining Technology Research based on CAXA

The impeller is a kind of contain complex surface more difficult machining parts, often through the UG, Pro/E and CAM software production parts processing program. In this paper, ME2020 domestic CAXA software as a platform, the impeller machining method.In order to improve the machining efficiency of the impeller, and gives the VERICUT software optimization program method.

Calculation method of cutter location points considering corner transition speed in CNC

The calculation method of cutter location (CL) points only considers the geometric errors, but cannot consider the requirements of the corner transition algorithm in CNC, which results in the smoothing algorithm in the CNC not playing a maximum role or even failing. To solve this problem, a calculation method of the CL points considering corner transition speed in CNC is proposed. Firstly, the key geometric parameters of the CL points that affect the corner speed are analyzed. Secondly, according to the analysis results, the objective function is established to connect the CL points calculation in CAM and the corner transition speed in CNC. By solving the objective function, the calculation method of the CL points is developed. Finally, the effectiveness of this method is verified by experiment. Comparing with the commonly used iso-chord height method, the proposed method can increase the speed at the corner of the CL points and reduce the acceleration and jerk at the same time. By the proposed method, the tracking accuracy, trajectory accuracy, and machining efficiency can be significantly improved. The proposed method can be integrated into CAM software to generate high quality CL points.

Cutting Parameters Optimization for Minimal Total Operation Time in Turning POM-C Cylindrical Stocks into Parts with Continuous Profile Using a PCD Cutting Tool

Turning is a complex machining process that can be characterized by a number of performances for a given machining system, workpiece material, cutting tool, and selected cutting regime. In addition to the characteristics of the machined surface quality, the estimation of machining time is particularly important for manufacturers, since machining time is directly related to other important performances of the turning process, such as productivity, cost, and energy consumption. In this paper, a model for estimation of total operation time in turning of a part with continuous profile, made of polyoxymethylene copolymer (POM-C), using a polycrystalline diamond (PCD) cutting tool, was developed. Face centred central composite design (CCD) and Box–Cox transformation approaches were applied for that purpose. The developed model was then used as the objective function in the proposed optimization model, which also included three practical constraints related to quality of the machined surface (surface roughness and workpiece deflection) and machinability aspects of the workpiece material (favourable chip forms). Nonlinear and linear models, used as constraints, were developed based on the results of experimental investigation of turning of POM-C using a PCD cutting tool. The total operation time estimation model showed good agreement with the results of tool path simulations in CAM software and validation experimental trial in real manufacturing environment. By applying the optimal solution, 44% of the total time being saved for machining of a single part can be achieved, compared to the recommended cutting parameter values, which indicates significant optimization benefits in turning industrial plastics.

Smoothing and compressing algorithm of toolpath with complex contour in NC machining

The continuous short line segment processing method in CNC machining has the defect of frequent fluctuation of feedrate, which affects the quality and efficiency. For this problem, the local and global methods are common solutions. The local method is to insert transition curves at the corners to obtain a smooth toolpath, but this method does not essentially reduce the number of accelerations and decelerations, and it is difficult to insert transition curves between tiny straight sections. Although the global method can obtain smooth tool trajectories, the parametric interpolation method is not suitable for middle- and low-end CNC machine tools. The article proposes an adaptive tool path generation method with the original part contour as the research object and discretizes the NURBS curves into smooth trajectories consisting of large segments of straight lines and circular arcs. The article mimics the crawling characteristics of snakes and designs a double-headed snake algorithm based on the least squares method to implement this process. First, given the start and end points of the curve, two snakeheads search for the maximum linear and circular segments that satisfy the error constraint in the curve direction. The winner will then be selected as the candidate track segment through a competition mechanism. Finally, all trajectory segments are connected to obtain a smooth tool path. Experiments show that the toolpath data of the method in this paper are reduced by 75.56% compared with commercial CAM software when the contour error threshold is the same, and the contour error is reduced by more than one order of magnitude when the number of toolpath segments is equal. In addition, the method in this paper can obtain a smoother machining surface and more stable cutting force, thus achieving a win‒win situation of quality and efficiency.

Development of CNC machine code and user interface for a 3-axis pneumatically configurable polishing machine

The polishing of freeform surfaces finds applications in a variety of niche areas where the surface characteristics have a defining impact on functional capabilities of the product. Pneumatically Configurable Polishing (PCP) is a recent addition to the available technologies which can generate surface finish of nanometric scales on freeform surfaces. The manipulative ease and determinism in polishing force control offered by the PCP process allow it to finish complex surface profiles in a highly repeatable way. The automation code for a CNC PCP machine-tool is developed to ensure the accuracy in the finished parts being produced. The machine code for CNC interpolation and the parametric process control have been carried out in the Parker Automation Manager software. The user interface has been designed and deployed using the JMobile HMI software. The PAM Visualization allows the user defined part program to be loaded in the controller from an external removable disk. The exchange of tags and process variables between the controller and HMI has been done using the OPC UA platform. A part program created using a CAM software is employed to finish a sample workpiece. The developed CNC machine code is successfully tested and evaluated for its functional performance and process repeatability.

Switching Software Pays Dividends

Devon-based toolmaker Tooltech reaps rewards of investing in new CAM software; and Tennant Company brings automated tooling process to light with software switch; plus, products in brief

High- performance manufacturing with trochoidal milling strategies

Along with technological progress, manufacturing processes have been constantly innovated, hoping to reduce manufacturing time, extend the useful life of tools and offer high quality finishes of the product, however, information on the product is scarce. Machined in 7075 - T6 aluminum, which, due to its mechanical properties, is more used for the manufacture of molds and dies than other materials. In this project, a high-performance machining is studied, improving cycle times by comparing trochoidal and conventional milling roughing strategies, without the use of coolants that can contaminate the chip allowing the recycling of material, these strategies are found in a large part of CAM software. The experimentation was carried out in a Hision CFV 1100 vertical machining center with Fanuc Oi MF control, supported by the Taguchi L18 methodology for the milling parameters and roughing strategy. 9 tests were carried out for each strategy with a 25 mm flat cutting tool with 4 high speed steel (HSS) lips based on the 3 levels of the milling parameters, in the range of 800 m / min to 1000 m / min, with a feed per tooth of 0.25 to 0.35 mm / tooth. The results obtained for both time and temperature have a behavior described by Mr. Salomón for high-speed machining (HSM), an ANOVA statistical analysis was carried out that determined that the trochoidal machining strategy presents a reduction in the 93.27% compared to the conventional machining strategy and a stable temperature of 25ºC in the cutting tool.

CAD-CAE-CAM technology in the manufacture of a 3-jaw independent chuck prototype in acrylic

The use and application of CAD, CAE, CAM systems are increasingly necessary in the industry, (Arriaga Segundo, 1999) To meet the needs of the accelerated industrial transformation that is taking place in industrially developed and developing countries, it is essential that those involved in the Mexican metalworking industry. In the technological area, there is a machining center for 4 axes, of which only 3 are used, due to not having a chuck for the 4th axis, which is necessary to manufacture more complex parts, and to prepare future engineers in the use of this technology. For this reason, an acrylic mandrel prototype was designed and manufactured using CAD, CAM and CAE technology. To demonstrate its application and usefulness in the manufacture of complex parts. First, the components that make it up were designed in CAD software: clamps, "worm" screw and casing, to later carry out the finite analysis in CAE software, computer-aided engineering, ending with the simulation and manufacturing in CAM software. This will validate and demonstrate the feasibility of manufacturing the mandrel in steel, with existing resources and with a design that best suits the requirements.

Analiza stabilności skrawania z dużą prędkością stopów aluminium

Progress in the production of cutting tools, CNC machine tools, and CAM software has contributed to improvement in subtractive machining processes, including milling, the so-called high speed cutting (HSC) and high performance cutting (HPC) machining. The cutting parameters that define the boundaries between the aforementioned technologies and conventional machining are not clearly defined. This is due to the close correlation between the process conditions and the types of processed material. High speed cutting and high performance cutting can be used for processing such as: machining of materials in the hardened state, machining without cutting fluid and with minimal lubrication, and thin-wall integral aerospace structures. The study examined complex analyses of HSC machining due to the process stability. The test results prove the dominant influence of cutting speed changes on a method’s effectiveness for spindle speeds up to 80,000 rpm.

Custom Bone Regeneration (CBR): An Alternative Method of Bone Augmentation-A Case Series Study.

We performed this clinical study in order to evaluate the reliability of the Guided Bone Regeneration (GBR) surgical technique through the use of customized CAD CAM titanium meshes (Yxoss CBR® Reoss) in order to show an alternative method of bone augmentation. Materials and methods: Nine patients presenting 10 bone defects were referred to solve oral dysfunction due to edentulous atrophic ridges. Guided bone regeneration was performed with titanium meshes combined with autogenous bone grafting and heterologous bovine bone mineral grafting, and exclusively a “poncho technique” soft tissue approach for all the cases. After a mean 9 months of graft healing (range 6–12 months), titanium meshes were removed, and implant surgery was subsequently performed. The results we obtained were positive in terms of volumetric increases in height, length and thickness of the atrophic ridges without biological complications detectable before implant surgery. Results: Out of nine, one site met titanium mesh exposure: however, in all 10 sites a three-dimensional volumetric bone implementation was obtained. The statistical results were estimated by uploading and superimposing cbct scans before and after CBR surgery for each patient, so it was possible evaluate the maximum linear vertical and horizontal bone gain through dedicated Cad Cam software (Exocad GmbH®). The average horizontal gain was 6.37 ± 2.17 mm (range 2.78–9.12 mm) and vertical gain was 5.95 ± 2.06 mm (range 2.68–9.02 mm). A total of 18 implants were placed into the grafted sites with a 100% survival rate (clearly they are relative percentages to be compared to the short time elapsed). Conclusions: The results we obtained in this study suggest that this CBR procedure (Yxoss® by Reoss) is reliable and safe for bone regeneration to allow implant-prosthetic restoration in horizontal, vertical and combined bone defects. The soft tissue management is diriment: all the cases were managed with a “poncho” flap approach to decrease exposure complication.

A FRAME WORK FOR SEAMLESS INTEGRATION OF DESIGN AND MANUFACTURING USING CNC

Machining is an important manufacturing process that is used in a wide range of applications. From aerospace applications to the manufacturing of energy systems we see a major reliance on machining. Nowadays, CNC machining is found in many industries to aid production by manufacturing process. CNC machining is absolutely essential for manufacturing and it is important. Some major benefits of CNC machining is manufacturing are greater efficiency, more accuracy and fabrication. In this project focus on gaining an improved understanding of the mechanics of machining and different factors that contribute to part quality. The aim of this work is to develop a frame work for seamless integration of design and manufacturing using CNC machine. For this process involves some steps. The selection of the component and design a 3D model of the component using CATIA software is presented here. Later generate the tool paths and program (contains G & M codes) using Dell CAM software. A post processor is used to converts the CAM data into specific commands that can be read a machine controller to move the cutting tool along the programmed paths. After the basic selections and decisions the preparation of a program will be done. After the lots of observation will go for fabrication of component using CNC vertical milling machine to achieve a designed shape with smooth finished surface, high accuracy and less machining time which directly increases the productivity.