Numerical Control Program Research Articles

Efficiency of Implementation of Modern CNC Equipment for Production of Heat Reducer Shafts

The article analyses the capabilities of modern metal-working equipment with numerical program control (CNC) and the efficiency of its use in the processing of gear shafts of diesel locomotives. Figure.3 the strategy of accelerating the socio-economic development of the country provides for the comprehensive intensification of production on the basis of scientific and technological progress. One of the effective ways to solve the problem of intensification of production, increase productivity is the introduction of modern CNC metalworking equipment and modern cutting tools. The industry has accumulated extensive experience in the use of CNC machines, which in comparison with conventional equipment create a number of technical and economic advantages. The productivity of these machines is three times higher than in machines of the same type without software control, and the need for production space is three times less. The greatest effect is given by CNC machines at processing of surfaces of difficult form and big accuracy therefore their use allows to reduce highly skilled workers.

Project-Based Teaching of a Manufacturing Class During the COVID-19 Pandemic

Abstract The plastics engineering program at the University of Massachusetts Lowell has taught mold design and engineering to undergraduate students for over 60 years. In 2020, the unexpected arrival of the COVID-19 pandemic in March forced the instructors to revisit the class program and objectives. Similar to other academic courses, the class became virtual. This meant redesigning an intensive hands-on manufacturing class into one that could be taught and taken from our home offices while maintaining academic rigor and continuing to meet critical student learning objectives. The timing of the pandemic meant that students, who were completing tooling split designs and starting computer numerical control programming, could not move forward with machining, assembly, and molding. Instead, their projects became virtual learning experiences. This paper provides the analysis and discussion of how new ideas in teaching were implemented to virtually introduce engineering students to the world of plastic manufacturing. The students' work was carried out on plastic part designs of their choice, some of which included thin walls (<2 mm) and microscale features (∼800 μm) typical of a micro-injection molding process.

Prompt Estimation of Die and Mold Machining Time by AI Without NC Program

Machining time estimation is essential for the due-date estimation of products as well as for production planning. Conventionally, machining time has been estimated by a computer aided manufacturing (CAM) system, which requires time and effort to create its numerical control (NC) program and requires machining expertise to operate it. In addition, among the problems with conventional methods, an error in the estimated machining time arises owing to the machine tool’s control characteristics. In this study, an artificial intelligence (AI)-based system capable of estimating machining time promptly and simply based on shape data without requiring any NC program is developed. The input data to the AI system are color information regarding the machined depths, which are used to estimate the rough-machining time, and color information regarding the machined surface curvature distributions to estimate the finish-machining time. Color information on the machined depths and machined surface curvature distributions is created using three-dimensional computer aided design (3D CAD) data. To build the AI system, the shape data and machining time data accumulated at the machining site are used, so that the machining time estimated reflects the machining method, machining expertise, and the machine tool characteristics employed.

Time-Varying Error Prediction and Compensation for Movement Axis of CNC Machine Tool Based on Digital Twin

Currently, it is a challenging issue to predict the thermal-induced time-varying error for the movement axis of the computer numerical control (CNC) machine tool. Subsequently, it is a challenge to predict the machining accuracy for a certain workpiece when the machine tool and numerical control program are determined. In order to resolve this shortcoming, the time-varying error prediction and compensation for the movement axis of the CNC machine tool was studied in this article, and the advantage of digital twin in predicting the changing trend for the physical entity was applied. The framework of time-varying error prediction and compensation for the CNC machine tool's movement axis was proposed based on the digital twin concept, which includes the physical entity layer, data transmission layer, function execution layer, and application service layer. The digital twin of the movement axis, containing a time-varying error model based on heat transfer theory and visual model, was created and packaged as a ready-to-use software for predicting and compensating time-varying error. The prediction experiment of the hole-pitch time-varying error for a workpiece was carried out. It was found that the difference between prediction error and actual error is only −0.2–2.6 <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">μ</i> m. The fluctuation range of hole-pitch error is reduced by 69.19% with the time-varying error compensation in real-time. The experimental results show that the method of time-varying error prediction and compensation based on a digital twin is an effective and feasible scheme.

Research on the calculation method of the ultra-precision turning trajectory of large-vector high-convex cylinders

Array microstructure optical elements are widely used in various beam homogenization occasions, but conventional processing methods cannot meet the accuracy requirements of large-sagittal convex cylindrical arrays. In this paper, the ultra-precision turning forming method is used to analyze the main factors affecting diamond turning, the sequential search method and the binary search method are designed to find the turning track, and the advantages and disadvantages of the two methods are compared. Furthermore, the binary search method is successfully found by combining the Matlab software turning trajectory and the numerical control program. As proof-of-concept demonstrations, turning experiments are carried on an ultra-precision lathe, and a large-vector high-array microstructure with a surface profile error of 135 nm is obtained. It proves that the force binary search method can accurately obtain the turning trajectory, and this method can be applied to both spherical and aspherical contours, showing important engineering application value.

Development of instructional materials based on mobile learning media (MLM) and its benefits

This study aims to develop a learning model based on Mobile Learning Media (MLM), test its effectiveness, and describe its benefits. MLM was developed for Computer Numerical Control (CNC) programming courses in vocational high schools. The effectiveness is tested by indicators of students’ higher-order thinking skills (HOTS). Advantages are explored based on their performance in learning. Recently, CNC programming lesson is known as a difficult subject because it requires critical and creative thinking skills. The research design was experimental with a pretest-posttest random control group pattern. Research respondents totaled 120 students with 60 students in the experimental class and 60 students in the control class. The research data includes data on the effectiveness of the model and student learning outcomes. Analysis of research data used descriptive statistical techniques and independent sample T-test with the help of SPSS 2.0 software. The results showed that the use of MLM was effective to improve teacher performance in teaching. MLM can facilitate students to develop HOTS. This is proved by the increase in student learning outcomes after the application of MLM. Based on the analysis of answers accompanied by reasons, students are able to show significant improvement in all critical and creative thinking processes.

Optimization of Tool Path for Surface Machining Based on Accuracy

Surface machining is the key technology in numerical control (NC) machining, and the planning of tool path is the basis and key of NC programming. Based on the improvement of the precision and efficiency of surface machining, this work analyzes the approximation machining error of NC machining of multi-coordinate surface. The tool step and calculation of cutting distance for tool path are discussed. The principle of tool path planning during surface NC machining programming is proposed, and the track verification is carried out with examples.

Simulation and experimental research of digital manufacturing based on reverse engineering

Reverse innovative design has long been an important subject in the engineering field. In this paper, two different-curved desk lamp stands were studied. The point cloud data of the stands was collected by using Win3D scanner and Geomagic Wrap software. Then, after facial processing of the data, reverse innovation of the facial data was performed through the reverse design software of Geomagic Design X to develop a new desk lamp stand that can satisfy engineering applications. It is actually an upgrading of the appearance of the original desk lamp stand. Finally, the numerical control program of the new desk lamp stand was completed through the processing module of UG software, and the program was verified by simulation and was used for experimental sample machining. Experimental results showed that the difference between the processed sample and the research model was less than 0.02 mm, indicating that the new design can satisfy engineering requirements and replace the original desk lamp stand. This means that reverse design technology is highly compatible with machining technology, which can shorten the innovative design period of product.

Design and realization of cutting simulation function of digital twin system of CNC machine tool

Abstract CNC machine tool processing is an important part of the current development of machinery modernization. In order to ensure the accuracy and stable quality of numerical control machining, the ecoding of numerical control program needs to be a validation to avoid in the process of the program which may leads to under-cut issue or collision case. Therefore, in the numerical control machining application process, you need to use digital twin technology to numerical control machining simulation cutting simulation, to verify the numerical control process is reasonable with the accuracy of a comprehensive, objective judgment, to avoid various abnormal situations have occurred in the process and to improve processing and production efficiency and quality.

Аналіз конструкцій плоскопритиральних верстатів

One of the methods of material processing is considered, which allows to obtain high geometric accuracy and low surface roughness of parts, namely their abrasive finishing. The high quality of machining of parts in this way is due to the use of coordinated relative movement of the workpiece and the cutting tool. According to the kinematic features, most lapping machines can be divided into two groups: machines with oscillating working motion and machines with rotating lapping motion. The machines of the first group are more common due to the simplicity of their design and versatility. However, the possibility of their use is limited by the size range of the workpieces and uneven wear of the cutting tool and, as a consequence, the uneven surface treatment of the part. The machines of the second group are considered the most versatile, as they allow processing a wide range of parts, varying in shape and size, but they are also not without such a disadvantage as uneven wear of the cutting tool with all the corresponding consequences. Improving the efficiency of abrasive finishing by complicating the trajectory of the relative movement of the tool and the part, ie the formation of a unique mutual working movement of the lapping and the movement of the workpiece, is one of the most common areas. The main disadvantage of equipment that provides processing of parts on this principle is, in most cases, limited regulation of the operating parameters of the cutting process, so this area remains promising and has broad prospects for development. The constructive scheme of the hydraulic-pulse flat-lapping machine offered in work thanks to a combination of advantages of the hydraulic-pulse drive with use of numerical program control will allow to provide unique mutual multi-movement of preparation and the lapping tool with a possibility of adjustment of its parameters in the course of processing. Purposeful choice of the shape and density of the trajectory of the working movement of the tool will form a micro relief of the treated surface with the necessary statistical parameters and low roughness.

The concept of digital twins for tech operator training simulator design for mining and processing industry

According to the top-priority trends and challenges in the mineral sector, and as per the mining science strategy, it is highly critical to arrange enhanced control, prediction and safety of production objects and their functioning for the preservation of automation sustainability. Improved control of databases, regulatory bonds, management, logistics and principles of sustainable development in mining makes it possible to reduce technological deviations and accidents at large mining and processing plants. Most procedural violations and accidents in surface and underground mines occur because of the unskilled actions of process flow operators. Damage in this case can be considerable, especially as compared with the expenses connected with qualitative training and persistent development of personnel engaged with supervisory control and data acquisition for the efficient operation of SCADA-systems within the automation framework of mining and processing plants. Definition of digital systems and their interrelation with multilevel automated control can be incorrect. The review of new principles can awaken interest in the conceptual assessment of digitalization processes using such notions as: numerical models, simulator, and artificial intelligence. Often applied formulations and principles of a digital model are substituted without justification of functional connections. On the other hand, a digital system today can be assumed as robotic lines and other numerical models and smart technologies, for instance, machining stations with numerical program control. It is necessary to define the practical significance of conceptual modifications and digital transformation regarding objects of the mineral sector, using Big Data; to understand how a digital twin can influence a changeable process situation; to provide prompt prediction; to eliminate an accident; and to preserve the physical balance in the whole production system. Such intelligent and flexible productions particularly need computerbased simulators and digital twins based on technologies of Industry 4.0–extended and virtual reality on the basis of digital twins. Digital twins allow maximal simulation of real-life activity of process flow operators. The skills acquired by personnel after such simulation training enable operators to master the optimized procedure for functioning in emergency situations in mineral mining and processing. This paper exemplifies the remote training and control of process flows, which is of concern in the current international situation.

CAD Integration of Mechanical Numerical Control Board Parts Based on Machining Features

The development and application of computer-aided design (CAD) technology has led to rapid improvements in product design automation, crafting process automation and numerical control programming automation. Machining feature refers to basic configuration units that constitute part shapes and the collection of non-geometric information with engineering semantics attached to it. The integration of mechanical numerical control parts is the integration of part design features and machining features, and each feature corresponds to a set of processing methods. Based on the summaries and analyses of previous research works, this paper expounded the current status and significance of mechanical numerical control board part integration, elaborated the development background, current status and future challenges of machining features and CAD technology, introduced a data transfer method of CAD integration and machining features-based part integration system, analyzed the design and machining features of CAD integration of board parts, constructed the graphics processing model and information reorganization model for CAD integration of board parts; conducted the feature description and modeling analysis of CAD integration of plate parts; discussed the crafting information similarity of mechanical numerical control plate part integration; explored the feature information and expression of feature library for plate parts integration.

CNC PROGRAM AND PROGRAMMING OF CNC MACHINE

A programming to make parts are CNC Programming (Computer Numerical Control Programming) for machines. An NC program consists of a sequence of instructions that control the motion and automatic sequences of an NC Machine to perform a particular processing task. In a general sense, the term NC programming refers to the creation of control data for machining workpieces on NC and CNC machines. NC programming has a decisive influence on the cost-effectiveness and profitability of NC manufacturing. The selection of a programming system is mostly guided by the need for software that is suitable for the application at hand, readily available, and as universally applicable as possible.

Research on the Innovation of NC Machining Process Based on Programming Technology

With the continuous development of China’s computer technology, China’s numerical control technology has also been widely used, concentrated in the process of processing complex parts. In the actual application of digital control technology, its operability is relatively strong, and has a strong portability and scalability, is an important part of the manufacturing in the field of integrated and automated machinery. In this paper, first of all, the numerical control processing technology and the numerical control programming technology are summarized; secondly, the complex model numerical control processing process flow is analyzed; finally its practical application is explored.

Tool Path Generation for 5-Axis Rough Cutting Using Haptic Device

CAM software is generally used to generate tool paths for 5-axis controlled machining. However, adjusting its several parameters and settings is difficult. We propose a system for tool path generation to be applied to 5-axis controlled machining. The system allows machining movements to be established by manipulating haptic devices in a virtual environment. Therefore, the cutter location for 5-axis machining can be easily controlled by operating a virtual cutting tool. The contact between the cutting tool and the target shape is reflected to the user through the haptic device. The generated path can be converted into a numerical control program for the actual machining of the target object. We detail the implementation of the proposed interface using two haptic devices and a method of tool path generation that improves rough cutting by smoothing the generated cutting points and simplifying the tool postures. The effectiveness of the developed system is confirmed through machining simulations.

Experimental Analysis of the Influence of Depth of Cut, Time of Cut, and Machining Speed on Vibration Frequency during Turning of AL1060 Alloy

Machining vibration is a significant concern in the manufacturing industry, as vibration cannot be eliminated during metal to metal turning operations. It can be controlled to the minimum when a proper study is carryout before the turning process. This study aims to experimentally analyse the effect of the individual parameters such as depth of cut (DOC) and cutting speed have on the machining vibration during turning of AL1060 alloy. A computer numerical control (CNC) program was applied to investigate the effects of the different depths of cut such as 1 mm, 1.5 mm, 2 mm, 2.5 mm, and 3 mm. Moreover, cutting speed of 200 m/min, 350 m/min, 500 m/min, and 600 m/min with a constant feed rate of 5 mm/rev have on the machining vibration during the turning process. DTO 32105 frequency analyser an MXC-1600 digital frequency counter was employed to measure the machining vibration for a specific time between 15 seconds to 500 seconds. The result shows that as the depth of cut continually increases, the machining vibration increases and the minimum machining vibration of 131.8 Hz was obtained at cutting speed of 600 m/min, depth of cut of 1 mm, and cutting time of 15 sec. The Pareto chart was further used to analysis the average vibration frequency at the optimised cutting speed of 600 m/min. The surface quality and the cutting tool life can be significantly enhanced with the study of the individual machining parameters.

Investigations on printing path dependent properties of additively manufactured samples using micro computed tomography

Purpose The purpose of this paper is to understand the relationship between defect properties and the tool path used for generating additively manufactured parts. The correlation between processing strategy and porosity architecture is one of the key aspects for a precise understanding of defect formation and possibilities for defect reduction. Design/methodology/approach The authors present a new combined geometry, processing path and porosity analysis procedure based on the use of x-ray computed micro tomography image data and numerical control programming code. The procedure allows for a covisualisation of the track of the respective processing head with the three-dimensional microstructure data. Findings The presented method yields statistical results about defect distribution and morphologies introduced by the respective process characteristics in parts. The functionality of the proposed procedure is demonstrated on an aluminum (AlSi10Mg) and a polylactide test sample to show the additional insight found for both additive manufacturing processes and the resulting microstructural properties. Originality/value The novelty of this paper is the analysis of the porosity with respect to the underlying additive process zone and the sample geometry.

CAD-CAM технології проєктування та виготовлення деталей на верстатах з ЧПК

The paper investigates the use of CAD-CAM technologies for the design and manufacture of parts on machines with numerical program control (CNC). These technologies allow designing technological routes of processing of surfaces of details of various complexity and making them on modern processing centers with CNC, and their use in the conditions of small-scale, single productions is justified and economically rational.Many operating enterprises in various industries have long been using technological equipment that is morally and physically obsolete. As a rule, wear parts (spare parts) are no longer produced for them. Replacement of obsolete technological equipment in the existing technological schemes of the production process of the enterprise requires significant material and financial costs, and its repair is complicated by the lack of spare parts. Therefore the question of manufacturing by the individual order of the enterprise of a small amount of worn out details for increase of maintainability of the operating technological equipment is actual.The article is devoted to the study of the possibilities of using CAD-CAM software systems «Autodesk Inventor», «ESPRIT» and «Creo Parametric» for the manufacture of custom worn impeller centrifugal electric pump KM 65-50-220, installed in the water treatment system of the food process .The step-by-step sequence of designing and manufacturing of a new improved (modernized) part instead of worn-out, possibilities and advantages of modern CAD-CAM software complexes, technological possibilities of CNC equipment is investigated. It is shown that the use of CAD-CAM systems «Autodesk Inventor», «Esprit» and «Creo Parametric» and a modern machining center Haas UMC-750 with CNC for the manufacture of a new improved design of the impeller of the electric pump, in single production, has significantly reduced technological time, preparation for the manufacture and replacement of worn parts, to improve the quality, reliability, durability and maintainability of the equipment operating at the enterprise.

Research and development of monitoring system and data monitoring system and data acquisition of CNC machine tool in intelligent manufacturing

Intelligent manufacturing as the development direction of the new generation manufacturing system has become a hot research topic. Computer numerical control (CNC) machine tools are the core manufacturing equipment in discrete manufacturing enterprises, collecting and monitoring the data is an important part of intelligent manufacturing workshops. It has a great significance to improve the production efficiency of enterprises and eliminate information islands. The purpose of this article is to solve the problems of data acquisition and monitoring of CNC machine tools in the manufacturing workshop of enterprises. This article uses FOCAS data acquisition method to research and develop the data acquisition and monitoring system of CNC machine tools in intelligent manufacturing workshop. The research results show that the equipment information model based on MTConnect protocol and FOCAS can solve the data acquisition and storage functions of CNC machine tools well. Using the object-oriented Petri net model, it can solve various uncertain factors in numerical control (NC) machining tasks and realize the monitoring function of CNC machining tasks in the workshop. Based on the NC program analysis, the calculation method of machining time in the NC program can determine the preventive maintenance cycle of the machine based on the machine fault information. Based on VS2013 development environment, Qt application framework and SQL Server 2012 database, the numerical control machine tool data acquisition and monitoring prototype system was developed, and the system was verified in the workshop to prove the effectiveness of the system.

Research on sealing ring complex curved surface grinding technology

In order to solve the problem of the precision machining of the complex surface of the hydrodynamic seal ring, the precision grinding equipment is used to grind the complex surface. According to the surface structure of the sealing ring, a grinding mathematical model is established, adopting radial ring stacking method and trigonometric formulas to calculate the grinding wheel center movement trace during precision spot grinding. It can provide a strict theoretical basis for the next ultra-precision grinding experiment. According to the movement track, the numerical control program is compiled, and the grinding test of the seal ring is carried out on the self-developed equipment. During the grinding process, the workpiece and the grinding wheel run smoothly. The seal ring test sample meeting the requirements of the face shape is processed, which solves the technical problem of processing the complex face shape. It provides reliable technical support for the subsequent high-precision processing and universal application of the seal ring.