CNC Operation Research Articles

Optimisation of Structural Design in Benchtop CNC Milling Machines for Enhanced Performance and Efficiency

This paper presents the design and optimisation of a cost-effective benchtop three-axis CNC milling machine aimed at improving performance and precision. Beginning with a conservative design, topology optimisation using Altair SolidThinking Inspire software was employed. Static and modal analyses revealed significant improvements in the optimised structure's integrity and dynamic performance, confirmed through Finite Element Analysis (FEA) and impact hammer tests. The machine features affordable components and standard PC interfaces, ensuring high performance while maintaining low costs. Accuracy tests, including circularity and straightness assessments, identified optimal spindle speeds and feed rates for precision machining. The optimised design showed reduced static displacement and enhanced vibration resistance, ensuring reliable operations. This CNC milling machine, suitable for educational and small-scale manufacturing environments, offers a compact, affordable and user-friendly tool for teaching CNC operations and programming. The study highlights the importance of structural optimisation in CNC machine design, demonstrating notable performance gains through advanced engineering.

An ontology of 3D environment where a simulated manipulation task takes place (ENVON)

Thanks to the advent of robotics in shopfloor and warehouse environments, control rooms need to seamlessly exchange information regarding the dynamically changing 3D environment to facilitate tasks and path planning for the robots. Adding to the complexity, this type of environment is heterogeneous as it includes both free space and various types of rigid bodies (equipment, materials, humans etc.). At the same time, 3D environment-related information is also required by the virtual applications (e.g., VR techniques) for the behavioral study of CAD-based product models or simulation of CNC operations. In past research, information models for such heterogeneous 3D environments are often built without ensuring connection among different levels of abstractions required for different applications. For addressing such multiple points of view and modelling requirements for 3D objects and environments, this paper proposes an ontology model that integrates the contextual, topologic, and geometric information of both the rigid bodies and the free space. The ontology provides an evolvable knowledge model that can support simulated task-related information in general. This ontology aims to greatly improve interoperability as a path planning system (e.g., robot) and will be able to deal with different applications by simply updating the contextual semantics related to some targeted application while keeping the geometric and topological models intact by leveraging the semantic link among the models.

Circular Economy in Manufacturing: Optimization using Lean Six Sigma

This research examines the amalgamation of Circular Economy concepts with Lean Six Sigma approaches to enhance manufacturing operations, emphasizing waste minimization, resource efficiency, and economic performance. The study assesses the influence of Lean Six Sigma on production efficiency and environmental sustainability via empirical analysis and process optimization methodologies. Conventional manufacturing procedures, including machining, milling, and grinding, were assessed for resource utilization and waste production, revealing that Lean Six Sigma methodologies markedly decreased material waste, especially in milling operations, where waste was curtailed by 20%. Advanced precision techniques, including CNC and laser cutting, were evaluated for their efficiency, with CNC cutting realizing a 15% decrease in energy usage and a 30% enhancement in material utilization. Laser cutting exhibited improved accuracy, resulting in a 35% decrease in rework and scrap. The economic study indicated that the application of Lean Six Sigma in CNC operations resulted in a 25% reduction in operating expenses over time, albeit greater initial expenditures. These results provide significant insights into the enhancement of industrial efficiency and the promotion of sustainable production practices via the integration of Circular Economy concepts with Lean Six Sigma methodologies. Keywords: Circular Economy, Precision Manufacturing, Comparative Analysis, Tool Life, Economic Implications.

Analysis of the Possibility of Introducing the Reduction of Changeover Time of Selected CNC Machines Using the SMED Method

Abstract The paper presents the results of improving the production process using the SMED method. The process improvement was carried out in a company in the construction industry, using a machine park consisting of CNC machines. The study evaluated the current state of changeover times for selected CNC machines and proposed a reduction in changeover times for the machine park analysed. By introducing changes to the changeover process on selected CNC machines, it was possible to minimise the changeover time by more than 20% on all the machines analysed. The proposed reorganisation of the CNC operators’ workstations resulted in a time reduction of approximately 61% for machine 1, 52% for machine 2 and 12% for machine 3. The installation of barcode readers on the profiles, on the other hand, made it possible to load the machining programmes into the CNC machines more quickly and resulted in a reduction in loading time of approximately 88% on average for each of the machines analysed.

Turning inserts the selection approach based on fuzzy comprehensive evaluation

Tool selection is a multi-criteria decision-making problem in the presence of various selection criteria and a set of alternatives, but previous works are limited to evaluating the tools within the workshop tool library. To intelligently select proper inserts across suppliers under the Internet environment, an insert data format based on ISO 513 was established, and a framework was then designed to obtain a set of alternatives from different suppliers based on fuzzy intervals. Then, knowledge was described with convenient language and the simple membership function to build an intelligent system, which would infer the matching degree of insert characteristics to the machining conditions. Furthermore, analytic hierarchy process was applied to sort the alternatives. Finally, the case study shows that compared with previous works and machinists, this work not only obtains a set of alternatives from all suppliers who uploaded their product data with the designed format but comprehensively evaluates the insert (take finishing low-carbon steel as an example, both cemented carbide and cermet are recommended, the nose radius reduces 25%, the environmental index increases 25%, while the rake reduces 11.25%, when compared with machinists who tend to select the larger rake angle foe finishing). A platform was also developed based on Visual Studio 2015 and SQL Server 2012 to improve selection efficiency for inexperienced CNC operators, purchasers, and vendors.

IMPROVE PRODUCTIVITY THROUGH DIGITAL MANUFACTURING

In the future the digitalization and "Industry 4.0” will be in every step of the product lifecycle from design to the manufacture, service, and maintenance. Through digitalization, the companies will be able to operate and program the complex CNC machine tools that will be ready to respond more flexibly to the market demands and at the same time to boost their productivity. Work preparation and production can be breaking down further into additional process steps, ranging from tendering to quality assurance. The demand for digitalization solution can be illustrated thru the following targets and questions what every production company must define and establish: 1. How long time will be the part on the machine to be manufacturi; 2. Is that CNC machine tools (what is able and have the technical characteristics) available; 3. Are necessary new cutting tools for this new job; 4.The CNC operator is familiar with the CNC control equipment; 5. Does the workpiece tolerance correspond with the customer specifications. Is not so easy to link up all this requests and to find the best solutions in time and to have high productivity. Digital manufacturing will give us the preliminary units costs and delivery deadline that must be determined to be able to tender for a job correctly. Today, the amount of time a workpiece will require for machining can be calculated quickly reliably and very important, without trial runs, using CNC simulation solutions. This recommendations from our paper can be an answer at the production companies and the advantage of this implementations is that can be made step by step. The solution of this implementation should be in concordance with the company’s requirements and resources.

Examine the optimal position of controls and display in computer numerical control machines

In Engineering Industries suffering due to industrial wound and ill health, of the Computer Numerical Control machines operators are in the increasing trend, in the subjective analysis which we carried out for the CNC machine, the operators expressing the discomfort at the neck, upper back, lower back, shoulder, and arm because of working with the keys in the controls and viewing the display. The aim of this examination is to identify the most favourable location of control and display through various muscles that activate while performing in CNC machine operations. We introduce surface Electromyogram (EMG) to determine the muscle activity and deliberate on plane of the body close to respective muscles of an operator.The muscle activity measured for all the twenty subjects, at five different levels to find out the best optimal location for controls and display to establish the findings of the subjective study. Though there is no clear trend when all the subjects are aggregated, it is seen that 90 cm-100 cm be the optimum range for the midpoint of the control panel and 143cm-148 cm appears to be the optimum range for the midpoint of the display. Since changes in muscle activity are comparatively small for all the six muscles taken for study, however, the effect of cumulative activity borne over a shift, week, month, and year are to be considered. Muscle activity may increase in repetitive head/finger movements. These combined effects are to be captured for the ergonomic design of the CNC operator interface.

Combined Drilling and Reaming Operation in Robot and CNC

The drilling and reaming operation are two separate machining processes. In our project drilling and reaming operation are combined by using combined drilling and reaming bit. The industrial robot with agile motion is possible to machine a component. The Industrial robots with high precision and six Degree of freedom are considered as better, for manufacturing processes. This work is to significantly compare the performance of robot drilling over CNC drilling. The manipulator used is ABB - IRB1410 with work volume of 2.6 meters, handling capacity of 5Kg and controlled by IRC5 Controller. Drilling machine utilized is specified with maximum speed of 2800 RPM and power of 600W. The speed of the drilling machine can be varied by using voltage regulator. Speed and feed are the two parameter that are varied and circularity, surface roughness are the parameter checked for. The drilling operation is also done in CNC machine. The parameters such as surface roughness, circularity are checked. Finally, comparisons between robot operation and CNC operation are performed, optimized values are found by using Taguchi method.

The Link and Match between the Competency of Vocational High Schools Graduates and the Industry on CAD/ CAM and CNC

This study describes (1) the work process analysis of the production stage in the industry, (2) the required competency and skills of CAD/ CAM and CNC in the industry, (3) the implementation of the basic competency of CAD/ CAM and CNC in vocational high schools, (4) the link and match between the competency of vocational high schools graduates and the industry on CAD/ CAM and CNC. The descriptive-qualitative method was employed by involving 8 people from Mega Andalan Kalasan Ltd (MAK) and 5 people from vocational high schools. The data were collected through observation and interviews which were further analyzed descriptively. The findings indicate (1) the work process analysis map the competencies that must be owned by the workforce including CAD drafter, CAM programmer, and CNC operators in which each workforce involved 4 work process sequences, (2) the competency of CAD/ CAM and CNC described the knowledge and psychomotor activities. In detail, the activity of the CNC machine setting produced knowledge competence and the skills of 36.5% and 26.7% respectively. The operating CNC machine produced the knowledge competence and skills of 25.4% and 23.3% respectively. The 3D drawing and 2D CAD systems produced the knowledge competence and skills of 19% and 23.3% respectively, CAM Programming generated the knowledge competence and skills of 19% and 26.7% respectively, (3) the implementation of basic competencies can be categorized as good, (4) there are two competencies fulfilled the link and match between the vocational high schools' competencies and industry, namely manufacturing drawing competency with CAD as well as mechanical competency with CNC and CAM.

A Review of Recent Application of Machining Techniques, based on the Phenomena of CNC Machining Operations

This review paper focus on the application of various machining techniques based on the phenomena of CNC operations, the study of different machining operations cannot be over emphasized due to its importance in the area of manufacturing and production companies. Therefore, this paper has study various application of this CNC machining techniques such as minimum quantity lubricant, cryogenic cooling, flood cooling, dry, high pressure coolant, compressed air / vapour /gas as coolant, solid lubricant/cooling and vegetable oil and their effect during machining for sustainable development and the study concluded that researcher still need to carry out more research on a single unique technique that can operate with multi-delivery lubrication method.

Bulanık AHP'ye dayalı staj değerlendirme ve işe alım: mobilya sektöründe bir uygulama

The choice of a newly personnel to hire is a decision making problem that requires evaluation of many factors being not totally known in terms of enterprises. That the success of this process is as significant as may not be left for coincidences. Therefore, staff selection problems should be resolved with scientific methods. This study aims to carry out trainee recruitment by means of the Fuzzy Analytic Hierarchy Process (FAHP) method being from one of the multi criteria decision making methods in a furniture factory. For this purpose, it was guaranteed by the enterprise that a student shall be hired as a CNC operator before the internship and this was notified to trainees in advance. Three students having satisfied the preconditions of enterprise were started the internship. The students were subjected to the evaluation at the end of training course and the most successful trainee among them was accepted for the job. In evaluation process the intern’s linguistic variables were used and the defuzzification of fuzzy weights was carried out based on the α-cutting and optimism index.

Designing a Novel Feeding System for CNC Turning Machines

Machining is a manufacturing process widely used in the industry that directly impacts on technological development. The machining processes are carried out by machine tools, which may have manual, automatic or CNC operation. The automatic machines are suitable for the production of parts with complex geometry and/or when it is necessary to produce parts on a large scale. In cases where there is a need to produce parts in large amounts, typically fully automatic CNC machines and processes are used, which increases the production capacity of the companies. These machines require equipment capable of feeding the raw material to the inside of the machine tools. For that, throughout this work is developed the mechanical design of a bar feeder machine for CNC turning centres, that will operate with low cycle time and can be operated safely and in a quick way by the operator.

Design of an expert system for the prediction and comprehensive diagnosis of CNC machining fault

Unlike the earlier research works which only focused on fault diagnosis, in this paper a smart fault preventive step is taken in avoiding some category of failures which may be predicted at the initial stage of CNC operation before a fault is diagnosed. Besides this, the domain of fault diagnosis has also been expanded by incorporating human error which was not part of the earlier system. This is the first phase of the study and a comprehensive fault diagnosis expert system algorithm for CNC machine is going to be designed, which can later on be transformed into a knowledge-based intelligent computer applications program. This will be accomplished by consulting experts on various aspects of CNC operations.

STEP-compliant CNC with T-spline enabled toolpath generation capability

The STEP-compliant CNC (STEP-CNC) system has been under research for years, and has been considered to be able to undertake various intelligent functions that cannot be performed by conventional CNC operations based on G-code (ISO 6983). However, the toolpath generation capability requires great developing and computing efforts, thus has gradually become a major obstacle on the future path of STEP-CNC. Due to the complexity and inherent flaws of the currently used tensor-product parametric surface (such as NURBS), the freeform surface machining in recent STEP-CNC prototypes mostly relies on the off-line toolpath generator in a CAM system. This paper explores the possibility to implement T-spline in a STEP-CNC system, so as to enhance the on-line toolpath generation capability for machining freeform surfaces. A set of toolpath generation algorithms with high robustness and efficiency is proposed for T-spline according to the machining strategy defined in ISO 14649. A practical STEP-CNC system has been developed, which parses the ISO 14649-based STEP-NC code with the T-spline extension, generates the toolpath on-line, and drives the servo axes directly. Some examples have been tested to show the feasibility as well as the efficiency of the STEP-NC compliant T-spline direct interpolation technology for the STEP-CNC system.

Application and Research on CNC Operation Panel Based on PMAC

Based on the matrix keyboard with PMAC motion controller built-in PLC design program, the program is used for control of machine tool control panel. In a quick feed ratio knob button as an example, the key code is given. Compiled by the control program is simple, has the versatility and portability, great savings with PMAC motion controller I/O points, reduce the cost, and application in VNCZT - 545 machining center.

DIAGNOSTIC OF CNC LATHE WITH QC 20 BALLBAR SYSTEM

This paper presents the evaluation of the influence of the feedmotion speed on the value of selected geometric errors of CNC lathe CTX 310 eco by DMG, indentified by QC 20 Ballbar system. Diagnostically evaluated were: the deviation of the axis squareness, reversal spike, and backlash. These errors determine the forming of the dimensional and shape accuracy of a machine tool. The article discusses the process of the CNC diagnostic test, the diagnostic evaluation and formulates guidelines on further CNC operation. The results of measurements were presented in tables and diagrams.

Life Prediction of a Spindle CNC Machining Centre Using Natural Frequency Method of Vibration

In the performance of a spindle CNC system, its bearings play an important role. Many problems arising in a spindle CNC operation are linked to bearing faults. In this project, the accuracy of the instruments and devices used to monitor and control the motor system is highly dependent on the dynamic performance of its bearings. Thus, fault diagnosis of a motor system is inseparably related to the diagnosis of the bearing assembly. In this paper, bearing vibration frequency features are discussed for spindle CNC of bearing fault diagnosis. This paper then presents an approach for life prediction of spindle CNC rolling bearing using nonlinear regression analysis. Vibration data are used to assist in the design for controlling and rolling bearing fault diagnosis strategies. Then our results obtained indicate that controlling and rolling bearing fault diagnosis can be effective agents in life prediction and diagnosis.

Development of the Software for Ball Nut Grinding Process Based on Siemens 840D System

Based on the analysis of the grinding model and grinding process of ball nut, the grinding process software for ball nut is developed by using VB programming language and Access database technology. Afterwards, the software is integrated into the Siemens SINUMERIK 840D System. As a result, it realizes the database management of grinding parameters and the automatic generation of machining program, thereby simplifying the process of CNC operation and improving the production efficiency greatly.

Design and Fabrication Testing of Combined Multipurpose Jig and Fixture

This proposed method has to design and fabricate the Multipurpose Jig and Fixture, for that component which has been to reduce the manufacturing cycle time. When the component produced on a small size previously this is to produces the large quantities of requirements. The selective components requires for machining operations such as step milling, angle milling & boring and reaming. The few operations where been done in CNC and rest operations are carried out in Conventional machine tool. The proposed method has to be design and fabricated the multi-operational Fixture for the complete machining operations in a single machining centre. The Fixture design has will serve for the economic production for the component.

Development of a Virtual Milling Machining Center Simulation System with Switchable Modular Components

The application of traditional three-axis milling machine center is very popular and the related application technology is also much matured resulting in mechanical components to be machined with good quality. Machine tool has therefore become an inevitable facility in precision manufacturing. Furthermore, the pursuit of higher precision machining has thus demanding five-axis machine tool to be adopted owing to its flexibility and capability in machining more precise mechanical components in shorter time. However, one of the key factors for the popularity in smooth introduction of five-axis machine tool would be based on a very user friendly learning and teaching environment. This is partly because two more rotational axes in a five-axis machine tool could generate very complex toolpath movement that is out of the imagination of a general operator. Furthermore, the price of an industrial five-axis machine tool is not normally affordable by an educational institute; to the worse, the maintenance cost is also very high. There is very high risk for a novice to collide during the learning process and this will generally cause big worry of a teacher. This paper aims for the development of a virtual machining center simulation system with switchable modular components to ease the learning process in getting acquainted with a five-axis machine tool. A five-axis machine tool consists generally of two modules: (1) CNC controller and Operation panel, and (2) machine tool hardware. The developed system will provide the novice with four CNC controller with operation human machine interface (HMI), and three typical types of five-axis machine tool, Head-Head (HH), Head-Table (HT), and Table-Table (TT), are also supported. The developed modularized and switchable machining center simulation system has been successfully developed and is very helpful to both learner and teacher