CAM Software Research Articles

Proses Pembuatan Bearing Holder Menggunakan Mesin Bubut CNC DL-8TH dan Milling

CNC (Computer Numerical Controlled) machine is equipment used to operate the workpiece cutting process which is assisted by numerical control using a computer. SOLIDWORKS is one of the CAD software created by DASSAULT SYSTEMES used to design machining parts or machining parts arrangement in the form of assembling with a 3D display to represent the real part made or 2D display (drawing) for machining process drawings. SOLIDCAM is one of the CAM software developed by SOLIDCAM, Inc. It is used as a turning simulation tool in this research code, where the program can be generated for the next process, namely turning with predetermined turning parameters. The milling process is a reduction of material to form a product by rotating the cutter and each tooth feeding and the machine table moves left and right so that the material moves according to the table movement. There are 2 milling methods that can be done, namely by milling vertically and horizontally. The material used in this research is SS304 which is a low carbon steel. The last stage in the process of making this part is welding. Welding is a metal joining technique by melting some of the parent metal and filler with or adding metal and producing continuous metal.

Different Cavity Designs with Additional Wings Increase the Fracture Resistance of Inlay-Retained Monolithic Zirconia Fixed Dental Prostheses.

To evaluate the effect of different cavity designs and cement types on the fracture resistance of monolithic zirconia inlay-retained fixed dental prostheses (IRFDPs). Four study models consisting of a second premolar, a missing first molar, and a second molar were used for the different cavity designs. Four different inlay cavity designs were prepared: DO-MO (disto-occlusal-mesio-occlusal cavity), MOD-MOD (mesio-occlusodistal-mesio-occlusodistal cavity), WDO-WMO (DO-MO with additional wings), and WMOD-WMOD (MOD-MOD with additional wings). A total of 64 epoxy resin models were produced and scanned individually. IRFDPs were then fabricated from monolithic zirconia using CAD/ CAM software. The bonding surface of the IRFDPs was airborne particle abraded (50-μm alumina/2 MPa), then cemented onto the epoxy resin models using two cementation protocols (n = 8 per group): (1) P = cemented with Panavia SA Cement Plus Automix; and (2) Z/C = cemented with MDP-containing primer (Z-Prime Plus) combined with Calibra Universal resin cement. All IRFDPs were fatigued through thermal aging (6,000 cycles/5°C to 55°C) and chewing simulations (600,000 cycles × 50-N load, 2.1 Hz). All IRFDPs were then subjected to a fracture resistance test using a universal testing machine with a crosshead speed of 0.2 mm/minute. Data were statistically analyzed using one- and two-way ANOVA and Bonferroni multiple comparisons test (P = .001). The mean fracture load (N) of the designs were as follows: WMODWMOD = 1,111.1; WDO-WMO = 1,057.4; MOD-MOD = 725.6; DO-MO = 682.7. According to two-way ANOVA, the differences among the cavity designs were statistically significant (P < .05). The cavity design of IRFDPs affected the fracture resistance. However, the fracture resistance of monolithic zirconia IRFDPs with any cavity design was enough to withstand expected posterior chewing forces.

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 &amp; 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.

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.

EVALUATION OF 3-AXIS AND 5-AXIS MILLING STRATEGIES WHEN MACHINING FREEFORM SURFACE FEATURES

The article deals with the comparison and evaluation of milling strategies, which are available in CAM systems and are used for the production of components with freeform surfaces. For the purpose of the experiment a test sample with a repeating shape feature was designed. First half of the test sample shape features were machined using 3-Axis milling strategies while second half was performed with strategies available on 5-Axis CNC machining centre. Simulated machining times as well as virtually machined surfaces using color maps with deviation values were evaluated by employed CAM software. Obtained data was used to evaluate the performance of 3-Axis and 5-Axis milling centre both individually and mutually. These results will be used to compare software data with data obtained from real sample production. The main goal is to verify the reliability of the results provided by CAM systems in the production of parts with freeform feature surfaces.

Integrated Interface System of STEP Data Models for the Tool Path Generation

The STEP (STandard for the Exchange of Product model data) is a worldwide standard for exchanging products between diverse computer systems and industrial applications. STEP files (ISO 10303) contain 3D data in the universal data format with a boundary representation (B-rep) that allows the exchange of data models between CAD, CAM, and CNC systems. Traditionally, G-code generation relies on CAM software as an add-on, which incurs significant installation costs. The purpose of this paper is to describe the development of an Integrated Interface System (I2S) for Tool Path Generation (TPG) for the CNC milling operations utilizing neutral STEP files.The algorithm was interpreted in Hypertext Preprocessor (PHP) programming and produced a computer interface system that is capable to convert STEP file geometric data to G-code format.The geometric features of the sample block were modeled using a 3D CAD model. The result was validated using machining simulation, and the machining is performed on a three-axis CNC milling machine with a PC-based controller.In modern manufacturing systems based on Open Architecture Controller (OAC), the development of the I2S provides an alternative to generating machining tool paths and G-code by intercepting CAM software.

Design of a New Modular Reconfigurable Gripper

An entirely new reconfigurable gripper is designed and shown in this paper. The new gripper comprises six modular fingers, which can be rearranged to form any number of fingers between three and six. CAD, CAM, CAE, and PCB software Fusion 360 was used to design the gripper. Also, the gripper fingers are rotatable, so the finger bases can touch each other side-by-side and form one finger. In addition to showing the reconfigure ability of the gripper, several scenarios for grasping different shapes were presented and tested.

Optimization of a Filament Wound Hybrid Metal Composite Railway Axle Design Concept

This paper presents a numerical design method to develop a mass-minimized winding sequence for carbon fiber reinforced tubes to be manufactured by filament winding. This method combines the use of Altair Optistruct Finite Element Solver and CADWIND V9 CAM software to develop a winding sequence to implicitly compensate for the loss of stiffness due to fiber intertwining. Hence, it was specifically built to solve a stiffness-driven mass optimization design task of a hybrid metal composite railway axle, in which the design constraints were imposed by a previously developed design solution. However, in theory, it could be applied to the design of composite shafts for various applications.

СОВЕРШЕНСТВОВАНИЕ КАЧЕСТВА РАБОЧИХ АЛГОРИТМОВ УПРАВЛЯЮЩИХ ПРОГРАММ СТАНКОВ С ЧПУ НА ОСНОВЕ СРАВНИТЕЛЬНОГО АНАЛИЗА СОВРЕМЕННЫХ ПРОГРАММ CNC И CAD/CAM

This article discusses the possibility of using modern CNC and CAD / CAM software, to create algorithms for automating the writing of NC for CNC machines, using the example of Sinutrain and Solidworks programs, and also highlights the main quality problems that complicate the process of automating the creation of NC.

Machining of elliptical curve profile for application in manufacturing industries

Manufacture of products with freeform curves is the need of the day in manufacturing industries like turbine blades, automobile bodies, aerofoils etc. Such profiles are usually manufactured on high precision machines. High precision (CNC) machines are required to enhance product quality at a reasonable cost. CNC programs with preparatory codes (G01, G02, or G03) provide automation, but the machines are restricted to the ability of linear and circular interpolators. Hence, due to the unavailability of appropriate preparatory function, machining of these curved shaped components causes difficulty on CNC machines. The CAD / CAM software divides the profile into the numbers of small linear segments. The transmission of the linear segments from software to CNC machine is subjected to errors. It results in noise and lost data. The discontinuity of the freeform toolpath deteriorates the surface quality and shape accuracy due to linear segments. To enhance the shape accuracy and surface quality, the numbers of linear segments are to be increased. Each linear segment to be machined is adding a single block in the part program. It will increase the size of the part program and program memory size at the cost of the surface quality. To achieve better surface quality and shape accuracy, MACRO programming is required. In the present work, the freeform regular axis-symmetrical profile (i.e. ellipse) is machined on mild steel (MS) and aluminum material using NURBS as well as Hermite interpolators. The curved profiles machined by MACRO and conventional programming methods are examined to measure surface quality using surface roughness tester (i.e., Mitutoyo SJ-210®), while toolpath deviation is examined with the actual profile plotted with CAD software (i.e., AutoCAD®). Radial and chordal errors are the least in the case of NURBS interpolation compared to Hermite interpolation. A better surface finish is observed while the elliptical profile is machined on mild steel and aluminium with MACRO programming

Multi-Body dynamic simulation of a machining robot driven by CAM

The use of industrial robots for milling processes has been targeted by many industries lately, as they are able to significantly increase the flexibility and lower the production cost over conventional CNC machines. However, the serial, open kinematic chain of industrial robots leads to a compromised structural stiffness, which in turn affects machining accuracy. Apart from that, the dependency of robot dynamic behavior on its posture requires time and cost intensive simulations and experiments to determine its dynamic behavior over its whole working envelope by using traditional methods. To this end, this work aims to develop an integrated model using the Multi-Body Simulation method for a machining robot, considering the elastic behavior of both the joints and the links. The links are modelled through the Finite Elements Method and the Craig-Bampton method is used to reduce the size of the model and enhance the computational efficiency. Moreover, the simulation is linked with a commercial CAM software to enable a rapid evaluation of the expected deflections over the programmed toolpaths and assist the process planning stage. Finally, a case study on a feed rate scheduling algorithm based on the simulation results is presented to showcase the capabilities of the developed model.

Dynamic analysis of a robot-based incremental sheet forming using Matlab-Simulink Simscape™ environment

This paper presents a dynamic analysis of a KUKA KR210-2 articulated robot used in single point incremental forming (SPIF) process. The development of a dynamic robot model offers the possibility to determine values of the joint torques during the SPIF process. This dynamic model of the KUKA robot was obtained by importing a three-dimensional (3D) CAD model of KUKA KR210-2 robot into Simulink-Simscape Multibody™ environment. By importing the CAD model into Simscape Multibody™, all mechanical characteristics of the robot were imported. To be able to drive the KUKA KR 210–2 robot on a certain user-imposed trajectory, solving the kinematic problem represents a necessary step. Solving the inverse kinematic problem is based on a geometric approach and is validated using Simscape Multibody™. To validate the developed dynamic model, a frustum cone geometry was chosen to perform the simulations. The input data for the dynamic model are represented by the user-imposed trajectory and the forming forces. The imposed trajectory was generated by a CAM software program, SprutCAM. The forming forces developed during the SPIF process was determined by means of a force transducer. The output data from the dynamic model are represented by the values of the joint torques developed during SPIF.

Orientation smoothing in multi-axis additive manufacturing

In multi-axis processes, such as material extrusion like Fused Filament Fabrication (FFF), the orientation of the tool relatively to the workspace is usually set by the CAM software to an angle that is locally constant relative to the manufacturing surface. However, in the case of large curvature gradients or small curvature radius of the surface or the path, this method leads to significant variations of the tool orientation. These variation require large compensating movements of the axes to maintain the desired deposition tool orientation along the path. Kinematic constraints such as acceleration or jerk limits can lead to a reduction of the path velocity or noticeable positioning errors along the movement, as well as unwante vibrations, which means poor process conditions and defects in the parts. The paper presents a post path planning algorithm that allows smooth in of the tool orientation to avoid jerky compensation motion of the CNC system by varying the orientation within a defined tolerance. This tolerance depends on the deposition process, and is determined experimentally for a FFF process. The proposed methodology was successfully validated b the manufacturing of two sample parts using a robotic additive manufacturing cell.

PERANCANGAN BANGKU PENDEK (DINGKLIK) BERBAHAN PLASTIK DENGAN BANTUAN SIMULASI CAD/CAE

Injection Molding is a thermoplastic material processing method in which the material that melts due to heating is injected by a plunger into the mold and then cooled until the material is solid, and removed from the mold.&#x0D; &#x0D; The purpose of this design is to determine the maximum load that can be accepted by the short bench (Dingklik), and to design the dimensions of the bench, while the design stages are as follows: starting from the design of the bench using CAD/CAE software, and machining simulation using can CAM software.&#x0D; &#x0D; Data input simulation is performed using the CAM software engine. The maximum weight of the respondent is 95 kg, and the load chosen to be safe in this design is 190 Kg (1862,9 N)&#x0D; &#x0D; The results of the design of the bench obtained the following data: length 350 mm, width 250 mm and height 180 mm, the material used is Polypropylene, the surface area of the object is 409923 mm2, the total volume with the gatting system is 776493,9461 mm3, and the maximum load that the material can withsatand is 2551.3995 Newtons.

NUMERICAL SIMULATION OF SINGLE POINT INCREMENTAL FORMING FOR ASYMMETRIC PARTS

Single point incremental forming (SPIF) that will produce non-symmetric sheet metal parts has been rarely dealt with so far. SPIF of a Francis hydro-turbine vane made of aluminum alloy is studied as a typical example in this work. At first, a concave geometry, encompassing the desired vane shape is designed, from which the formed part will be ultimately cut out. The necessary SPIF toolpaths are created by using the CAM software normally used for milling processes. Based on these toolpaths, a finite element simulation is setup using shell elements with a particular emphasis on substantial time scaling and due care on tool-sheet contact parameters. For validation purposes the part was manufactured and digitized by a white light scanner. It exhibited tolerable deviation from the targeted nominal geometry. Simulation predicted a significant part of this deviation, proving its indispensability in checking out toolpaths and process parameters for non-symmetric parts, yet at non-negligible computational time.

Machine Shop Investments Power Growth and Quality

Latest turning technology keeps IML at the front; WLR benefits from two new CMMs; Cutting Blue investment in machine tools and CAM software rewarded; plus, news from the latest Contract Manufacturing Index (CMI)

Proposal of a Machining Test to Evaluate Dynamic Synchronization Error of Rotary and Linear Axes With Reversal of Rotation Direction

Abstract The five-axis machining of a free-form surface often contains the reversal of a rotary axis’ rotation direction with linear axis synchronized with it. This paper proposes a new machining test to quantitatively evaluate the influence of the reversal of rotation direction on the surface geometry and roughness. In the five-axis machining, the trajectory of tool position and orientation is first given in the workpiece coordinate system (WCS) by the computer-aided manufacturing (cam) software, and the computerized numerical control (CNC) system converts it to the machine coordinate system (MCS) to calculate command trajectories. This paper clarifies that the tool path smoothing in the MCS can potentially cause a large contour error because of the dynamic synchronization error of rotary and linear axes. Although some academic works in the literature presented the smoothing in the WCS, many commercial CNC systems still employ the smoothing in the MCS, partly because machine tool users or makers do not clearly see how significant this influence can be on the machining accuracy. The proposed machining test enables a user to quantitatively evaluate it. The machining experiment shows that the geometric error of the finished test piece was as large as 0.16 mm under the conventional smoothing in a commercial CNC system, which can be significantly larger than the influence of other typical geometric errors of a five-axis machine tool. This paper shows, by numerical simulation, that the smoothing in the WCS can completely eliminate this contour error.

Online First-Order Machining Error Compensation for Thin-Walled Parts Considering Time-Varying Cutting Condition

Abstract Mirror error compensation is usually used to improve the machining precision of thin-walled parts. However, due to the time-varying cutting condition of thin-walled parts, this zero-order method may result in inadequate error compensation. To cope with this problem, an online first-order error compensation method is proposed for thin-walled parts. With this context, first, the time-varying cutting condition of thin-walled parts is defined with its in-process geometric and physical characteristics. Based on it, a first-order machining error compensation model is constructed. Then, before process starting, the theory geometric and physical characteristics of thin-walled parts are, respectively, obtained with CAM software and structure dynamic modification theory. After process performing, the real geometric characteristic of thin-walled parts is measured, and it is used to calculate the dimension error of thin-walled parts. Next, the error compensated value is evaluated to construct an error compensation surface, which is used to modify the tool center points of next process step. Finally, the machining error is compensated by performing the next process step. Two typical experiments, milling of thin-walled parts with plane- and curved-surface, are used to validate the proposed method, and the experiment results shown that this method can significantly improve the error compensation effect for low-stiffness structure. Compared with the mirror compensation, the final thickness error of thin-walled parts is reduced by 71.4% and 56.2%, respectively, for plane- and curved-surface parts.

Express Calculation of Machining Costs in CAM Software

Express Calculation of Machining Costs in CAM Software

Application of Computer-Aided Reverse Engineering System in the Design of Orthotic Boots for Clubfoot Patients

Clubfoot is an abnormal foot as a congenital disability in which one or both feet appear rotated inward and downward. In some cases, the foot and leg sizes may be smaller compared to each other. Accordingly, there is a need for customized shoes designed for clubfoot patients who has difficulty in wearing regular shoes to carry out their daily activities. This study examines using computer-aided reverse engineering system technology to design and manufacture customized boots with specific sizes and shapes. Reverse engineering with a handy scan 3D scanning tool with a tolerance of 0.001 mm was implemented to obtain 3D mesh data of the patient’s clubfoot (male with 65 years). The Curve Base Surface Modeling method provided 3D-CAD drawings of the insole and shoe, the last models, precisely and following the size and shape of the patient’s foot. This CAD data could be appropriately transferred to CNC machines and PowerMill CAM software to obtain patterns of insole and shoe-last from EVA foam rubber and wood. Both ways were well fitted with leather by a shoemaker into a pair of customized clubfoot boots. The field boot-wearing test used feedback from the clubfoot patient wear-testers to assess the functionality and acceptability of the boot products. In this way, the club foot patient can able to perceive wearing comfortably and perfectly. In the field boot-wearing test, the patient could walk at a speed of 83.1% -91.7% faster (2 - 5 minutes/foot) than that when the patient wears the old boot design model. Significantly, the present approach may add knowledge theoretically and practically to use CARE system-based technology in treating clubfoot patients with the need for custom shoes.