The mold manufacturing is one batch production that the same process does not repeat. The digital model in software is processed with a real mold fabricated in high performance without error. In this study process planning, and machining simulation software are integrated with a smart machine tool for the mold industry. It reduces the operational complexity to four button clicks after dragging and dropping of 3d model data to fabricate multiple-numbers of graphite electrodes. The smart machine tool fabricated 27 graphite electrodes with minimum interference of humans in 35 hours.
In CAD/CAM, NURBS (Non-Uniform Rational B-Spline) is used to represent a wide variety of free-form curves. NURBS interpolation is advantageous in the processing of smooth curves and is capable of high-speed and high-precision CNC machining. In this paper, a real-time 5-axis NURBS curve interpolator is proposed. The proposed interpolator is based on tool center point control and can produce smooth tool orientations as well as accurate tool paths, thereby realizing high precision and efficient 5-axis machining. Using newly defined G codes, tool orientations are described by vectors and the proposed interpolator can be applied to any 5-axis machines regardless of their rotary axis configurations. In addition, the proposed interpolator calculates both tool positions and orientations simultaneously using a shared interpolation routine and we can reduce the computation load. The proposed NURBS interpolator is implemented on a PC-based 5-axis CNC testbed. The performance of the proposed interpolator is compared with the conventional linear interpolator in terms of smoothness of feedrate, contour errors, and tool orientation errors.
This paper investigates the relationship between the preload level of a ball screw drive and the detected natural frequency of the system in an axial direction. A dynamic model to study the preload variation of the system is derived, and then a preload feature is proposed for extracting preload conditions based on the detected natural frequency of the system. A modified double-nut ball screw drive system with adjustable preload level is constructed. This is for the purpose of experimental verification. An accelerometer is attached to the ball screw nuts of the drive system to acquire vibration signals. The signals are analyzed to obtain the natural frequency of the ball screw drive system in an axial direction. By investigating the variation of the detected natural frequency, it is shown that the preload level can be diagnosed by the proposed preload feature. Both the experiment results and mathematical model show a direct correlation between the natural frequency and preload levels. Natural frequency increases when the preload level increases. This study provides a method to monitor the preload of a ball screw system which can be used as an indicator of the health status of the drive system.
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Tool wear is an essential parameter in determining tool life, machining quality and productivity. Current or power signals from motor drivers in machine have been used to estimate tool wear. However, accuracy of tool wear estimation was not enough to measure the amount of tool wear. In this study, flank wear of a drill tool was measured using vision sensor module which has zoom lens, CCD camera and image processing technique. The vision module was set up in the machine tool. Therefore, the image was acquired without ejecting the tool from the machine. Image processing techniques were used to define the cutting edge shape, tool diameter, and the wear edge on cutting rips with the proposed measuring algorithm. The automatically calculated wear value was compared with a manually measured value. As a result, the difference between the manual and the automatic methods was below 4.7%. The proposed method has an advantage to decrease the measuring time and improve measuring repeatability because the tool is measured holding chuck in a spindle.
The Human Machine Interface (HMI) is dependent on the Computerized Numerical Control (CNC). As a result, the HMI software is developed according to the interface method of each CNC in duplicate. Even though the same function of HMI software module is developed using the same data item, it must be implemented separately in different development environments. This is because each CNC has a different address system and provides unique data interface method. In this study, we proposed a unified interface system that can standardize and integrate data interface method to support the development of HMI software module applicable to machine tools adopting multi-vendors’ CNCs. To clearly define this work, we developed new parameters, methods, and address system based on the machine state model, composed of data elements of machine tool structure, process, and status, provides the same interface by capsulizing existing CNC interfaces. The proposed interface system is designed to provide an API (Application Programming Interface) in the form of a library. The implementation architecture is designed and details of the operating logic within the detailed components and interfaces are elaborated. The implementation and test results are illustrated to verify an application example of the proposed unified interface system.
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Wire feeding type directed energy deposition (DED) process is able to produce metal parts with high density at high deposition rate. However, the parts are subjected to high residual stresses and distortion due to its large heat input. In order to simulate the thermal stress, a proper heat input parameter is required. The goal of this paper is to investigate the efficiency and penetration depth of the applied heat flux in the DED process. The estimation method for the penetration depth and efficiency of applied heat flux is proposed using the thermal finite element analyses (FEAs). A finite element model is developed according to the cross sectional profile of the actual deposited beads. A top-hat volumetric heat flux is adopted to simulate the transient thermal phenomenon of the laser based wire feeding type DED process. The estimated heat affected zone (HAZ) from the FEAs is compared with the experimental results in order to estimate the proper efficiency and penetration depth of the laser beam for each condition of DED process.
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The heat-sealing strength of pouch film greatly affects the reliability of the lithium ion secondary battery. In this paper, the researchers investigated and evaluated the properties of the heat-sealing strength of pouch film, such as heat, pressure, time, thickness of the heat-seal, and the polypropylene material. The heat-sealing strength showed a high value at 180℃ for 3 seconds. However, under the conditions of higher temperatures and longer times, deformation and bulging of polypropylene were observed. The heat-sealing strength tended to increase when decreasing heat-seal thickness. The heat-sealing strength varied according to the type of polypropylene. In addition, to avoid defects that may have occurred in the process of manufacturing the lithium ion secondary battery, the heat-sealing strength in the state where the impurities remained was evaluated.
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