Browse Topic: Nonconventional machining processes

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Development of Predictive Models and Prediction of Process Parameters for Wire Electrical Discharge Machining of Monel 4002022-28-049111/18/2022
The numerous applications and desirable attributes of Monel 400 urge many researchers to undertake multiple systematic evaluation studies for diverse manufacturing operations. Because of their exceptional mechanical qualities and great corrosion resistance, nickel-based alloys, particularly Monel 400, are increasing in popularity in a variety of applications. Because of their tendency for rapid work hardening and low thermal conductivity, these materials are particularly difficult to machine using traditional manufacturing techniques. Advanced material removal methodologies have been applied to eliminate such drawbacks and are regarded as a suitable alternative approach to traditional machining processes. Based on the Electrical Discharge Machining technique, Wire Electrical Discharge Machining was developed, which a sophisticated machining technology is used to machine hard materials with complex forms in any electrically conducting materials. The machinability performance of Monel
Natarajan, Manikandan, Pasupuleti, Thejasree
Machinability Studies on Wire Electrical Discharge Machining (WEDM) of AA2014 alloy using Taguchi Grey Approach2021-28-026410/1/2021
AA 2014 is a copper based aluminium alloy which is having exceptional mechanical characteristics such as better strength, ductility and lesser fatigue. AA 2014 is most generally employed in various engineering applications such as fabrication of structural components, defense applications and manufacturing of aerospace components. Also, this material possess better resistant to corrosion which makes this material best suitable for numerous engineering applications. Unconventional methods of machining have been evolved for producing intricate shapes in electrically conductive components. Wire Electrical Discharge Machining (WEDM) is one among the unconventional machining method which is used for making intricate shape on any electrically conductive work material. In this work, an experimentation has been carried out on WEDM of AA 2014 alloy, employing Taguchi’s technique. The experimental runs have been conducted by taking into account, the process variables such as pulse-on-time, pulse
Navya, C., Chandra Sekhara Reddy PhD, M
Experimental Analysis on Wire Electrical Discharge Machining of Nickel Alloy Using Taguchi based Grey Relational Analysis2021-28-027310/1/2021
Nickel is one of the difficult to machine materials and exclusively employed in high temperature environments. This alloy possesses better strength and lesser thermal coefficient which makes the poor machining performance in conventional methods of machining. For overcoming such kind of demerits, nontraditional machining methods have been identified. Wire Electrical Discharge Machining (WEDM) is one among the advanced methods that is developed from the concept of Electrical Discharge Machining process that is predominantly engaged for machining of harder materials and also for producing intricate shapes. This present exploration deals about an experimental study on WEDM of nickel alloy and also mainly concentrating on the optimization of process variables using Taguchi based grey approach. The experimental trials are devised by Taguchi’s experimental design approach and process variables are analyzed by Taguchi’s single response analysis. Pulse on time, pulse off time and peak current
N, MANIKANDAN, Joseph Selvi, Binoj, KRISHNAMACHARY, P.C, Thejasree, P
Application of Taguchi approach on Wire Electrical Discharge Machining of SS3042021-28-027110/1/2021
SS304 (Stainless Steel 304) is a nickel- chromium based alloy, that is extensively used for the applications like cryogenic vessels, valves, refrigerator equipment and evaporators because of its high corrosion resistance, ductility and ability to remain as solid up to a temperature of 14000 C. SS304 is one of the tough to machine materials by conventional methods of machining. Wire Electrical Discharge Machining (WEDM) facilitates the ease of machining complicated cuts with hard to machine, conductive materials where high surface finish is required. In this investigation, a study has been done on WEDM of SS304 and mainly to optimize the process parameters during the machining of SS304 by using Taguchi’s analysis. Taguchi’s DoE approach is used to plan the experimental runs and by considering the process parameters such as pulse on time, pulse off time and peak current at three different levels the experiments were conducted. The performance measures considered in present analysis are
Thejasree, P., N, Manikandan, Krishnamachary, PC, Varaprasad, K C, Joseph Selvi, Binoj
Innovation on a Larger Scale: Robotic Fiber Placement and 3D PrintingTBMG-385062/1/2021
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Simple Robot Vision Tools Support Complex ApplicationsTBMG-3780810/1/2020
A new wave of easy-to-use robot vision systems allows companies with no automation experience to enjoy the benefits of vision-powered production. But can these no-fuss, low-cost systems support complex tasks like quality inspection?
An Inside Look at Maximizing Throughput, Speed, and Efficiency with Robotics in Medical Device ManufacturingTBMG-376839/1/2020
Recently I entered our stainless-steel tube processing area, which looks completely different from the way it did 10 years ago. The entire room used to be filled with people who were running machines, inspecting components, and working on changeovers. The company was a different place back then and was only starting to embrace automated work cells. Fast forward to today. When I walked into that room, I was greeted by one of our setup technicians sitting on a chair in the corner. I joked with him, “Don’t you have any work to do?” He replied, “Take a look around, you see all those green lights? If they are green, then I am doing my job.” There was no one else in the room but us, yet all of the machines were running. That was a powerful moment for me, and it was then that I realized we had transitioned almost every processing machine in that room to some form of automation.
Tesla casts a new strategy for lightweight structures20AUTP06_016/1/2020
The EV maker boldly invests in the world's largest aluminum die-casting machine to manufacture entire rear underbody structures. Aluminum is synonymous with “weight-saving” in most contemporary automotive-engineering reference points. But apart from a few applications - most notably Ford's F-Series pickups - aluminum largely is deployed where steel can be readily displaced without performance loss or for comparatively small components that deliver comparatively small weight or process savings. Electric-vehicle maker Tesla is readying the next step in aluminum use, however - one that effectively matches Ford's “big gain” approach by specifying a massive piece of structural die-cast aluminum for the rear underbody of the recently launched Model Y crossover. According to Tesla CEO Elon Musk, this new aluminum application represents a radical step for its design and manufacturing advantages and its light-weighting potential. Musk is renowned for outsized promises, but in the case of the
Visnic, Bill
Micromolding: Achieving Exacting Medical Device Manufacturing RequirementsTBMG-369295/1/2020
It is undoubtedly fair to say that one of the key sectors driving innovation in the area of micromolding is the medical device industry. Demand for minimally invasive curative and diagnostic procedures is growing exponentially, and because of this, medical device manufacturers have been designing (and seeking to manufacture) smaller and smaller components, with thinner walls, and complex and miniature features. Couple this with the overarching demand from patients and healthcare providers to rationalize the costs associated with medical treatment, and medical device OEMs are constantly on the lookout for cost-effective and efficient manufacturing processes.
Smart Manufacturing ControlTBMG-359972/1/2020
The manufacturing process of today involves many challenges, from mass production down to a lot size of one. The CNC controls in factories have to master this market trend without an adequate amount of skilled labor in the US manufacturing world. In essence, manufacturing is facing a renaissance in the CNC control technology shift.
Collaborative Automation: It's More Than Just the CobotTBMG-3560812/1/2019
Collaborative robots, often called “cobots,” offer opportunities for companies of almost any size to cost-effectively automate processes that were previously out of reach. Cobots are available in a wide range of sizes, payloads, and capabilities but they all share attributes that define the term “collaborative.” The aspect that most people think of first is safety — the ability for cobots to work alongside human workers without bulky, expensive guarding. Cobots include a number of built-in safety mechanisms including rounded edges and softer materials as well as power-and force-limiting technologies that avoid injury and minimize discomfort in case of contact, and sensors that automatically slow or stop the robot arm if a human enters its workspace.
Application of Response Surface Method to Optimize Waterjet Cutting Process Parameter of Glass Fiber Reinforced Polymer Matrix Laminates2019-28-015310/11/2019
Waterjet machining is a widely used advanced machining technique because of its versatility in removal of material for a wider range of materials. Waterjet machining is particularly advantageous in the precise cutting of advanced materials like Fiber Reinforced Polymers (FRPs) comparative to conventional machining methods. The conventional machining methods result in the release of high amount of glass fiber dust which leaves the work environment unsafe for the workers. The material dust if inhaled can lead to acute respiratory diseases. In this work an analysis was done on the cutting performance of Waterjet machining and is presented based on an experimental investigation on fabricated fiberglass reinforced laminates. It is shown that with a good combination of cutting parameters such as nozzle traverse speed, waterjet pressure, and Stand-off distance a cutting performance can be achieved. Plausible trends of kerf quality and machining time with respect to the waterjet pressure
Aulakh, Savitoj Singh, Patil, Dhanush, Elsen, Renold, Aggarwal, Sangeet
Investigation of Machinability Characteristics on Turning of Nimonic 90A Using Al 2 O 3 and CNT Nanoparticle in Groundnut Oil2019-28-007210/11/2019
Nimonic 90A alloy is a nickel-chromium-cobalt alloy and found as a potential material for turbine blades, discs, forgings, a ring section, and hot-working tools. This paper presents the effect of concentration along with cutting speed and feed rate on Fz: cutting force, Ra: surface roughness and Vba: tool wear with the application of two different nanofluids (NFS) on turning of Nimonic 90A by TiAlN PVD carbide cutting inserts. The nanoparticles suspended in oil taken for present investigation are nAl2O3, nCNT, and groundnut oil. The Taguchi L9 orthogonal array and derringer’s desirability response surface has been employed for parameter design and optimal search. 3D surface plots, factor effect plots, Taguchi S/N, and variance tests are used to study the effect of concentration on the machining performance of Nimonic 90A. The statistical analysis revealed % concentration for nCNT and cutting speed for nAl2O3 are found as an influenced parameter on performance characteristics. From the
Kannan, Venkatesan, Sundararajan, Devendiran
Optimization of Machining Process Parameters for Minimizing the Waste Stream Response through Multi-Objective Optimization2019-28-006210/11/2019
During the delivering of an item, any material created moreover to a definitive item will be named as waste. The waste produced in light of machining could be a notable conservation worry for creators. The shape and condition of waste streams created, and their transportation components divergence with the strategy utilized and also shift among the technique. The effect in view of each waste stream differs as well. This examination reports a machining strategy includes the procedure of material to give a completed or a semi-completed item. This is frequently done by misapplication tools, totaling, machines and distinctive data sources that are appropriate to the strategy. The procedures thought of for the point of this work includes machining of material manipulation devices to give parts and items. The yield of the technique incorporates the item and increase the waste streams. The waste streams will be in the form of Chips, Energy usage, and Worn cutting tools and Operating time
Sivam Sundarlingam Paramasivam, Sundar Singh, Loganathan, Ganesh Babu, Saravanan, Krishnaswamy, Kumaran, Durai, Rajendran, Raj, Sriram, Harish
Multi Response Optimization on Machining Titanium Alloy Using Taguchi-DEAR Analysis in Abrasive Water Jet Cutting2019-28-007010/11/2019
Abrasive water jet cutting has been proven to be an effective technology for processing various engineering materials. This paper investigated the effects of process parameters on depth of cut in abrasive water jet cutting of titanium alloy. Four different process parameters were undertaken for this study; water pressure, nozzle traverse speed, abrasive mass flow rate and standoff distance. The influence of these process parameters on depth of cut, surface roughness and MRR has been investigated and analyzed. An empirical model for the prediction of depth of cut in abrasive water jet cutting of cast iron has been developed using regression analysis. The approach is based on Taguchi-DEAR method to optimize the AWJM process parameter for effective machining. It has been found that the stand-off-distance has highest impact on performance measures among all process parameters.
Thangaraj, Muthuramalingam, Loganathan, Ganesh Babu, Atif, Akhtar, Palanisamy, Srinivasan
Fault Detection in Single Stage Helical Planetary Gearbox Using Artificial Neural Networks (ANN) and Decision Tree with Histogram Features2019-28-015110/11/2019
Drive train failures are most common in wind turbines. Lots of effort has been made to improve the reliability of the gearbox but the truth is that these efforts do not provide a lifetime solution. Majority of failures are caused by bearing and gearbox. It also states that wind turbine gearbox failure causes the highest downtime as the repair has to be done at Original Equipment Manufacturer [OEM]. This work aims to predict the failures in planetary gearbox using fault diagnosis technique and machine learning algorithms. In the proposed method the failing parts of the planetary gearbox are monitored with the help of accelerometer sensor mounted on the planetary gearbox casing which will record the vibrations. A prototype has been fabricated as a miniature of single stage planetary gearbox. The vibrations of the healthy gearbox, sun defect, planet defect and ring defect under loaded conditions are obtained. The signals show the performance characteristics of the gearbox condition. These
Shaul Hameed, Syed, Vaithiyanathan, Muralidharan, Kesavan, Mahendran
Vision Based Surface Roughness Characterization of Flat Surfaces Machined with EDM2019-28-014810/11/2019
Surface roughness measurement is an important one in any manufacturing next to dimensions. In this investigation, a vision system and image processing tools were used to develop reliable surface roughness characterization technique for Electrical Discharge Machined surfaces. A CMOS camera with red LED light source were used for capturing images of EDMed surfaces. A separate signal vector generated for all the images from its image pixel intensity matrices. The mean, skewness and kurtosis were obtained from the signal vector. The mean, skewness and kurtosis of the images signal vector correlates very well with the stylus measured hybrid roughness parameters Rda and Rdq. Hence the technique may be preferred for online surface roughness characterization of Electrical Discharge Machined (EDMed) surfaces.
Ali, Mahashar, Jailani, Siddhi, Mariappan, Murugan, Anandan, Mangalnath, Pavithran, Vignesh
Assessing Viscosity in Hydro-Erosive Grinding Process via Refractometry04-12-03-00128/22/2019
The manufacturing of diesel injector nozzles requires precision processing to produce multiple micro-holes. An abrasive fluid containing a mixture of mineral oil and hard particles is used for rounding them, ensuring the hydrodynamics of the injection. As verified in a previous investigation, the viscosity of the fluid undergoes uncontrolled changes during hydro-erosive (HE) grinding. Such undesired viscosity changes are detrimental to the process and difficult to assess. The current investigation aims to study the possibility of using the refractive index of the oils used in the HE grinding for assessing their viscosities. A calibration curve correlating the refractive index and viscosity was obtained from the analysis of samples produced by mixing two distinct mineral oils in different proportions. The determined calibration curve was tested with 45 samples of filtered oil, collected directly from the tanks during the HE grinding. The results showed that refractometry is a potential
Heidemann, Bárbara R., Scherpinski, Gustavo, Fabris, Luís, Muller, Marcia, Fabris, José L., Pintaude, Giuseppe
Cross-Training Made Possible by Common Control PlatformTBMG-345796/1/2019
EMAG L.L.C. is the U.S. subsidiary of a major German machine tool builder that specializes in machine tools for the production of automotive, off-highway, agricultural, and oil field components. The company’s equipment ranges from basic round part turning centers to large-workpiece, five-axis machining centers; gear hobbing machines; and alternative equipment such as laser welding and electrochemical machining centers. This wide variety of machine tools requires an assortment of control technologies to power and manage the motion. For one customer requirement where a major agricultural equipment builder needed grinding, turning, and turn-grind machines, EMAG looked to Siemens for a standardized CNC solution.
A New Method for Multi-objective Optimal Design of Milling Parameters by Considering Chatter Vibrations2019-01-50435/13/2019
The desired milling process with high material removal rate (MRR) and low surface roughness of the product can be achieved only if machining chatter is absent. Incorporating chatter into the optimal selection of the machining parameters leads to a complex problem. Therefore, the approach of selecting conservative intervals for the machining parameters is usually employed instead. In this paper, a practical approach is proposed to specify the optimal machining parameters (depth of cut and spindle speed) in order to maximize MRR and minimize forced vibrations by considering machining chatter. Firstly, the worst-case scenario-based optimization problem in terms of the surface quality is solved to find the critical time at which maximal amplitude vibrations occur. Then, the time dependency of the problem is eliminated. Secondly, the multi-objective optimization is conducted to achieve the Pareto Optimal Front (POF). The Stability Lobe Diagram (SLD) is obtained independently through well
Jafarzadeh, E., Khodaygan, S., Sohani, A.
Dynamic Modeling of CNC Drive Systems: Comparison of Two Models2019-01-08034/2/2019
Accurate positioning and precision of CNC machines are directly affected by performance of their mechanical drive system and control unit (CNC feeddrive system). This is more important in contouring operations where axes motion is synchronized by interpolators and errors are accumulative. This research work is focused on study of dynamics of the feeddrive unit. In this regard, a detailed dynamic model is developed in state-space format that is used to study its response properties. A parametric study of the system is carried out by studying shifts in eigenvalue loci when a parameter is changed. The results are used in further simplifying this model to a reduced order system which is simpler in structure and more appropriate for control applications. A comparison is made between these models and the merits of each individual model are presented.
Mehrabi, Mostafa
Digital Manufacturing Helps Medtech Firm's Goal to Improve Patient OutcomesTBMG-342614/1/2019
As often happens in the medical industry, innovative ideas hatched in university research settings spawn innovative companies, which create innovative products. A case in point: HemoSonics. The Charlottesville, VA-based medical device company was started in 2005 by two professors and a post-doctoral research student at the University of Virginia School of Medicine's Bio-Medical Engineering program — Bill Walker, Mike Lawrence, and Francesco Viola, respectively. The trio identified a method for measuring the stiffness of blood clots by using ultrasound imaging technology and created a system built around that technology aimed to improve patient outcomes and reduce costs.
Metal Additive ManufacturingTBMG-3336012/1/2018
Additive manufacturing (AM) – the process of building up solid layers of material to form a finished solid part — is an emerging and exciting technical discipline. Also referred to as “3D printing,” many misconceptions exist about the capabilities and promises of the technology.
ABNT 4140 steel mechanical properties after nitriding by EDM process2018-36-03259/3/2018
Electrical Discharge Machining process (EDM) is a non-conventional cutting method applicable for the machining of electrically conductible or semi-conductible, with no contact between the tool and the work piece which consists in an electrode and a work piece both submerged in a dielectric fluid and connected into a direct current source. Initially, the fluid behaves in an insulating way so that there is no electric current until a minimum gap between the electrode and the work piece is reached. Once this gap is reached, the dielectric fluid starts behaving in a conductive way creating a plasma channel due to the electric arc generated. Ion are emitted between the anode and the cathode thus colliding with the dielectric fluid molecules obtaining enough energy to fuse/vaporize and consequently removing material from the work piece/electrode. The main objective of this study was to adapt the conventional EDM machine, so that it could allow performing the NDE (Nitriding by Electrical
Quirino, Cid Clay, Neumann, Lucas
Diamond Pellet Grinding ToolTBMG-325108/1/2018
NASA Marshall Space Flight Center has developed a numerically controlled grinding tool that eliminates undesirable periodic variations in surface contours in optical and other surfaces — such as mid-spatial frequency errors — that result from polishing. It can also be used to eliminate any undesirable irregularities in optical surfaces — either flat, curved, or aspheric — as well as other precision surfaces such as orthopedic joint replacements.
Optimization of Process Parameters for Electro Discharge Machining of Al 7075-Al 2 O 3 Nano Composite Using Different Electrode Materials2018-28-00937/9/2018
In the present study, an aluminium based nanocomposite, reinforced with 2 wt. % aluminium oxide (Al2O3) is developed through stir casting method. These hard ceramic particles also influence the material removal rate (MRR), electrode wear rate (EWR) and surface finish (Ra) in an electro-discharge machining (EDM) process. In this work, EDM of Al 7075/2 wt. % Al2O3 nanocomposite is carried out using copper and brass electrodes using Taguchi L18 array. The percentage contribution of each process parameter on the response variables was determined using analysis of variance (ANOVA). Multi-response signal to noise ratio (MRSN) and the optimum combination levels for the input parameters was obtained using Taguchi’s parametric design. MRR and surface roughness are substantially improved when machining is performed at optimized conditions.
C, Kannan, Ramanujam PhD, R, Balan PhD, A S S, Vijayakumar, T, Karunakaran, C
Optimization of Electrical Discharge Machining of Titanium Alloy (Ti-6Al-4 V) Using Taguchi-DEAR Method2018-28-00327/9/2018
Electrical discharge machining (EDM) process is widely used unconventional machining process in manufacturing industry for machining high hardness materials and to make dies of complex cavities. In this work experiments are carried out during electric discharge machining of Titanium alloy (Ti-6Al-4 V). Taguchi L9 orthogonal array is used to conduct experiments. Process parameters, such as, peak current, pulse on time and pulse off time are chosen for this study. Whereas performance characteristics namely material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) are selected for this study. The significance of process parameters on performance characteristics is analyzed. The objective of present work is to find optimal combination of parameters that gives maximum MRR and minimum TWR and SR simultaneously. Taguchi-data envelopment analysis-based ranking method is used for above multi-response optimization.
Vaddi, Vikram Reddy, Ch, Sridhar Reddy, Pogaku, Vamshi Krishna, Bushaboina, Shiva Kumar
Application of TOPSIS with Taguchi Method for Multi-Attribute Optimization of Machining Parameters in EDM2018-28-00337/9/2018
The present work focused on application of TOPSIS along with Taguchi method to optimize machining parameters in Electrical Discharge Machining (EDM) of Titanium alloy (Ti-6Al-4 V) considering it as multi-attribute problem. The L9 orthogonal array of Taguchi method is used to conduct experiments. During experimentation Titanium alloy (Ti-6Al-4 V) is chosen as a work material and electrolyte copper is selected as a tool electrode. Whereas peak current, pulse on time and pulse off time are chosen as machining parameters. TOPSIS method is applied to determine the optimal combination of machining parameters to yield maximum material removal rate MRR), minimum tool wear rate (TWR) and surface roughness (SR) simultaneously. Confirmation experiments have been done at optimal parametric setting, then results are compared with predicted values and it was found that percentage error is less than 5.
Vaddi, Vikram Reddy, Ch, Sridhar Reddy, Bushaboina, Shiva Kumar, Banka, Hemasunder
Digital Manufacturing Helps Revolutionize Surgical StaplerTBMG-297487/1/2018
Modern science has allowed surgeons to fix the human body amazingly fast yet leave behind only small traces where repairs were performed. One of the more commonly used methods to achieve this is by a minimally invasive technique called laparoscopic surgery, where small incisions are made into a patient's skin, a laparoscope is inserted to provide a magnified view of the patient's organs, the procedure is performed, and the incision is closed by stitching or surgical staples. You can have your gallbladder removed before breakfast and be binge-watching Netflix from the comfort of your couch by dinner.
Advanced Techniques For The Fabrication Of Airframe Structures Using Innovative Friction Stir Welding (FSW) TechnologyF-0074-2018-128045/14/2018
ABSTRACT One of the alternative method for welding method is a friction stir welding (FSW), which was developed in 1991 at TWI (The Welding Institute) in the United Kingdom, initially especially for joining aluminum and its alloys [1]. This process consists in joining of materials in solid state, which eliminates the problems resulting from melting the material and its re-solidifying, such as, hot cracking, residual stresses and distortion created during conventional welding. In this process, the heat which plasticized the material is provided by rotating tool consisting of shoulder and pin. This tool penetrates into the base material and then moves along the welding line. As a result of the friction between tool and joining materials is generated a sufficient amount of heat allowing on mixed the base material and create FSW joint. Among the most important advantages of using the FSW method should be listed: relatively easy automatization (it is often possible to use conventional CNC
Luty, Grzegorz, Wronska, Agata, Andres, Jacek, Galaczynski, Tomasz
Multi-Axis Voxel-Based CNC Machining of Centrifugal Compressor AssembliesF-0074-2018-127985/14/2018
ABSTRACT The use of computer-aided manufacturing (CAM) software is essential in the rapid production of high-quality computer numerical control (CNC) machining toolpaths for complex parts. Typical CAM software relies on analytical representations of part geometry, where curves and surfaces are described by parametric functions. This paper proposes the use of a novel way to represent part geometry known as a voxel model. A voxel model uses a three-dimensional array of small cubes to represent a part volume; these cubes, or voxels, are the three-dimensional analog of two-dimensional pixels in an image. The use of voxels for a CAM application enables higher surface complexity, simplified collision checking, and more robust analysis of material removal than would be possible with typical parametric CAM. The unique capabilities of the voxel-based CAM approach described in this paper enable rapid production of high-quality 5-axis toolpaths for machining complex parts, such as the centrifugal
Kurfess, Thomas, Tucker, Tommy, Silberglied, Chelsea, Lynn, Roby, Saleeby, Kyle, Saldana, Christopher
Advanced Machining and Automation Reduce Medical Device Tubing CostsTBMG-2785411/1/2017
In order to stay competitive in today’s medical device marketplace, it is imperative that companies continually invest in the latest technologies to ensure that they produce the highest quality metal tubing products, while also reducing costs. To meet these demands, full-service contract manufacturing operations must also be vertically integrated to handle complex medical device tubing projects.
Referencing Strategies for High Accuracy Machining of Large Aircraft Components with Mobile Robotic Systems2017-01-21669/19/2017
The demand for higher production rates in aircraft industry requests more flexible manufacturing solutions. A bottleneck in production is the machining of large components by vast portal machines. Time-consuming referencing processes result in non-satisfying cost-effectiveness of these high-invest-machines. Mobile robot-based solutions are able to operate simultaneously which increases the productivity significantly. However, due to the limited workspace of robots, machining tasks have to be divided and long trajectories are separated in single overlapping segments. Thus high-accuracy referencing strategies are required to achieve desired production tolerances. In this publication different advanced optical reference strategies will be discussed taking the inhomogeneous behavior of a mobile robotic machining system into account. Investigations on the absolute positioning and the machining accuracy will show the impact of different referencing strategies on sub-scale machining
Susemihl, Hendrik, Brillinger, Christoph, Stürmer, Sven Philipp, Hansen, Stephan, Boehlmann, Christian, Kothe, Simon, Wollnack, Jörg, Hintze, Wolfgang
CPAC Bulkhead Riveting System2017-01-20749/19/2017
Ever increasing process applications inspire us, as suppliers of aircraft, structural-assembly, and equipment to design innovative and modular, manufacturing cells in compliance with modern specifications. The result is the new flexible C-Frame Panel Assembly Cell (CPAC) Bulkhead riveting System. This paper describes how benchmarks for flexible automated drilling and fastening are being achieved with the CPAC.
Dillhoefer, Thorsten, Erdinc, Fatih
Automated Riveting of C-130J Aft Fuselage Panels2017-01-20759/19/2017
Electroimpact and Lockheed Martin have developed an automated drilling and fastening system for C-130J aft fuselage panels. Numerous design and manufacturing challenges were addressed to incorporate the system into Lockheed Martin’s existing manufacturing paradigm and to adapt Electroimpact’s existing line of riveting machines for manufacture of these legacy aircraft parts. Challenges to automation included design of a very long yet sufficiently rigid and lightweight offset riveting anvil for fastening around deep circumferential frames, automated feeding of very short, “square” rivets in which the length is similar to the head diameter, creation of part programs and simulation models for legacy parts with no existing 3d manufacturing data, and crash protection for the aircraft part from machine collisions, given the uncertainties inherent in the model and the unique geometry of the aircraft parts. Additional challenges were overcome in integrating the system into Lockheed Martin’s
Bigoney, Burton, Huddleston, Nicholas
Drivmatic® Automatic Fastening System with Single Robot Positioner2017-01-20789/19/2017
The focus of this technical paper is a unique automatic fastening system configuration for loading, positioning & unloading pre-tacked door assemblies within a static C-Frame Drivmatic® fastening machine using an off-the-shelf, high accuracy Fanuc robot. In 2011, PMC was awarded a significant contract for supplying commercial OEM aircraft doors and recognized automation was the most feasible approach for fastening each door assembly. At the time of contract award, PMC was an established aero structure supplier with significant automation capability for machining high tolerance parts & assemblies and manual fastening resources to support many different OEM programs however PMC did not have automatic fastening experience or capability. In support of this new Tier-2 contract, PMC reached out to Gemcor to propose a collaborative robot solution for automatically fastening 5 different door assemblies that were historically fastened using a semi-automatic configuration. Demand for quality
Barton, Eric, Wolf, Rick
True Mobile/Portable Drilling and Machining, a Paradigm Shift in Manufacturing2017-01-20849/19/2017
The evolving Aerospace manufacturing environment has created challenges that until now are not achievable with standard machine tools, large monumental gantry style machines and robots, or even manually operations. The solution is a lightweight, mobile/portable, and modular PKM (Parallel Kinematics Machine) solution, capable of machining to high tolerances, with minimal time and effort to relocate to a different area, at an affordable price With the carbon fiber PKM module mounted on a mobile platform, the module can simply be relocated using a standard pallet mover or forklift, to all areas in a factory. The module can also be removed from the mobile platform by two people, and mounted in a desired location and in any orientation “in hours”. The modularity of the PKM does not only make it possible to move it around in different production areas, but also makes it possible to reconstruct in an area that is not typically accessible by machines or robots. Acting as a mobile machine tool
Neumann, Karl-Erik
Solid Lubricant Assisted Machining -An Environmental Friendly Clean Technology to Improve the Surface Quality2017-28-19647/10/2017
Machining of materials has received significant consideration due to the increasing use of machining processes in various industrial applications. In machining, the heat generated in the cutting zone during machining is critical in deciding the work piece quality. Lubricants are widely used to reduce the heat generation. Their usage poses threat to environment and health hazards. Hence, there is a need to identify eco-friendly and user-friendly alternatives to conventional cutting fluids. Modern tribology has facilitated the use of solid lubricants such as graphite, calcium fluoride, molybdenum disulphide, and boric acid as an alternative to cutting fluids in machining. Solid lubricant assisted machining is an environmental friendly clean technology for improving the surface quality of the machined work piece. The present work investigates the role of solid lubricant assisted machining with graphite lubricants on surface quality while machining EN 8 steel .The performance of solid
Ramamoorthy, Rajaganesh, Venkatesan, T., Rajendran, R.
Effect of Cryogenic Treatment of Copper Electrode on Electro-Discharge Machining2017-28-19627/10/2017
Cryogenic treatment is an ultra low temperature treatment technique. Effect of cryogenic treatment on properties of ferrous materials and alloys is well understood. Due to which, cryogenic treated materials are being used in various applications. One among them is Electro-Discharge Machining (EDM). In EDM, the replica of electrode is obtained on the work piece, during the process tool also worn out to certain extent. In order to reduce the tool wear rate cryogenic treatment can be applied to the tool material. In this paper, the effect of cryogenic treatment on electrode wear rate of electro-discharge machining for varied pulse ON time (EDM) was studied. The cryogenic treatment was applied to the copper electrode and the microstructure analysis was carried out using optical microscope. EDM experiment was conducted using untreated and cryogenic treated copper as electrode and High Speed Steel (HSS) as work piece. Electrical resistivity was also measured. From the microstructure analysis
Mouda, Pervaz Ahmed, Siddhi Jailani, H
Adding Simple Vision Systems to Collaborative RobotsTBMG-270766/1/2017
Adding vision to a collaborative robot can open a world of possibilities for automation applications. With a vision system, a robot can inspect parts, check specific features of a part, recognize a part to pick it up, count items, adjust its path using visual feedback, color sort, and so on. The breadth of applications requires careful consideration to ensure selection of the right technology for the job.
Open Core Engineering: New Freedom for Machine Automation ProgrammingTBMG-267174/1/2017
The increasing sophistication and complexity of medical devices is compounded by strict regulatory requirements that demand systems that can produce consistent, repeatable results. Automation has been key to achieving these goals while maximizing output and minimizing downtime.
Machine Health Prediction Enhancement Using Machine Learning2017-01-16253/28/2017
Use of sensors to monitor dynamic performance of machine tools at Ford’s powertrain machining plants has proven to be effective. The traditional approach to convert sensor data to actionable intelligence consists of identifying single features from cycle based signatures and setting thresholds above acceptable performance limits based on trials. The thresholds are used to discriminate between acceptable and unacceptable performance during each cycle and raise alarms if necessary. This approach requires a significant amount of resource & time intensive set up work up-front and considerable trial and error adjustments. The current state does not leverage patterns that might be discernible using multiple features simultaneously. This paper describes enhanced methods for processing the data using supervised and unsupervised machine learning methods. The objective of using these methods is to improve the prediction accuracy and reduce up-front set up. Classifiers such as KNN, Logistic
Kalamdani, Rajeev, Jalluri, Chandra, Hermiller, Stephen, Clifton, Robert
Artifact Based Assessment of CNC Machine Thermal Growth and Compensation2017-01-02993/28/2017
Thermal growth of spindle and other components is common in CNC machines, especially with MQL machining, and directly impacts positioning accuracy and thereby quality. A common method to address this is by measuring the thermal growth using gage bore probing and then compensating for it. Application of this method in 5-axis CNC machines is relatively new and effectiveness is often not tested. Error sources due to various orientations of the part could arise. A new artifact based method is presented for assessment of thermal compensation used by the CNC OEM. The method involves an artifact, test cycle and automated data logging. A precision granite artifact with gage bores on different faces is fabricated and can be presented for probing in different orientations. The machine is warmed up using repeated dry-cycling, thereby creating thermal growth. Compensation error is evaluated as the difference of actual thermal growth and compensation offset. Various metrics for overall compensation
Jalluri, Chandra, Rajoria, Himanshu, Goderis, Mark, Habel, Michael, Hill, Trevor
Aerospace Hydraulics and Actuation Lessons LearnedAIR4543/1A (Current)2/23/2017
This SAE Aerospace Information Report (AIR) contains Lessons Learned from aerospace actuation, control and fluid power systems technologies. The lessons were prepared by engineers from the aerospace industry and government services as part of the work of SAE Committee A-6, Aerospace Actuation, Control and Fluid Power Systems. Each lesson was presented to the appropriate A-6 technical panel. The technical topics are organized into five sections covering systems, actuation, hydraulic components, electrical components and miscellaneous, each further divided into subsections. The information topics are presented in a concise format of Problem, Issue, Solution and Lesson Learned, often with accompanying descriptive diagrams and illustrations for clarity and understanding.
A-6 Aerospace Actuation, Control and Fluid Power Systems
Accelerating Abrasives with the Greatest Precision to Produce Intricate Medical ComponentsTBMG-2558410/1/2016
The latest medical developments typically involve smaller, more precise structures. These can be implants, assemblies, or components and motors in robotic equipment. With the demand for smaller parts, the requirements for producing these parts have become more challenging.
Impact of the Fourth Industrial Revolution to Complex Aerospace “CFRP/Ti Drilling Applications” in Conjunction with Advanced Cutting Tool Design and Electric ADU’s2016-01-20999/27/2016
On CNC Machines, drilling holes under perfect condition is possible. For drilling holes into titanium, composite and aluminum stacked materials the specific cutting condition can be selected. Furthermore surrounding conditions such as peck cycle, MQL and force and torque monitoring can be easily adapted. When drilling holes in the final assembly, CNC machine tools cannot be employed due to sizes and accessibility. Power Feed Units or Automated Drill Units ADUs are very handy, flexible and depending upon the jig extremely rigid. Whenever a machine tool does not fit, ADUs are highly recommended. In comparison to machine tools, conventional pneumatic ADUs can be used with one fixed set of feed, speed and micro peck only. Due to that a compromise in cutting condition has to be chosen in drilling stacked material with different layers. In the mind-set of the fourth industrial revolution, this article presents a completely new approach in the ADU Technology, while the benefits in the
Mueller-Hummel, Peter, Langhorst, Thomas
Accuracy Analysis and Error Source Identification for Optimization of Robot Based Machining Systems for Aerospace Production2016-01-21379/27/2016
Strong market growth, upcoming global competition and the impact of customer-requirements in aerospace industry demand for more productive, flexible and cost-effective machining systems. Industrial robots have already demonstrated their advantages in smart and efficient production in a wide field of applications and industries. However, their use for machining of structural aircraft components is still obstructed by the disadvantage of low absolute accuracy and adverse reaction to process loads. This publication demonstrates and investigates different methods for performance assessment and optimization of robot-based machining systems. For conventional Cartesian CNC machining systems several methods and guidelines for performance assessment and error identification are available. Due to the attributes of a common 6-axis-robot serial kinematics these methods of decoupled and separated analysis fail, especially concerning optimization of the system. One main focus of this paper lies on a
Kothe, Simon, Stürmer, Sven Philipp von, Schmidt, Hans Christian, Boehlmann, Christian, Wollnack, Jörg, Hintze, Wolfgang
Development of Bicycle Surrogate for Bicyclist Pre-Collision System Evaluation2016-01-14474/5/2016
As part of active safety systems for reducing bicyclist fatalities and injuries, Bicyclist Pre-Collision System (BPCS), also known as Bicyclist Autonomous Emergency Braking System, is being studied currently by several vehicles manufactures. This paper describes the development of a surrogate bicyclist which includes a surrogate bicycle and a surrogate bicycle rider to support the development and evaluation of BPCS. The surrogate bicycle is designed to represent the visual and radar characteristics of real bicyclists in the United States. The size of bicycle surrogate mimics the 26 inch adult bicycle, which is the most popular adult bicycle sold in the US. The radar cross section (RCS) of the surrogate bicycle is designed based on RCS measurement of the real adult sized bicycles. The surrogate bicycle is constructed with detachable components with shatter resistant material to prevent structural damage during a collision, and matches the look and RCS of a real 26 inch mountain bicycle
Yi, Qiang, Chien, Stanley, Brink, Jason, Niu, Wensen, Li, Lingxi, Chen, Yaobin, Chen, Chi-Chen, Sherony, Rini, Takahashi, Hiroyuki
CAM Programming vs. Manual Programming in Medical MachiningTBMG-243794/1/2016
The manufacture of medical devices involves some of the most sophisticated machining processes found in industry today. From a machining perspective, the machine tools that make up the “back bone” of medical device machining are 5-axis Computer Numerical Control (CNC) Mills, Wire EDMs (Electrical Discharge Machining) and Swiss-type lathes. For years, computer aided manufacturing (CAM) software has been used to automate the programming of the first two of those machining operations: 5- axis CNC Mills and Wire EDMs. However, CNC Swiss have been slower to move CAM.
An Overview of Nitinol: Superelastic and Shape MemoryTBMG-2307710/1/2015
The world population is growing, globalization has resulted in a higher standard of living in many countries, and people are living longer. With increased living standards and choices people make, lifestyle-related illnesses, such as cardiovascular diseases, are on the increase. Companies race to make medical devices to cure challenging physical conditions and diseases. Novel materials are an integral part of supporting such design and development. One such material is Nitinol (NiTi), a serendipitous discovery in 1959 by William J. Buehler during research at the U.S. Naval Ordnance Laboratory, White Oak, MD. Nitinol, which saw use in medical devices beginning in the late 1980s, stands for Nickel Titanium Naval Ordnance Laboratory.
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