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Abstract

Optimization of industrial processes such as manufacturing or processing of specific materials is a point of interest for many researchers, and its application can lead not only to speeding up the processes in question, but also to reducing the energy cost incurred during them. This article presents a novel approach to optimizing the spindle motion of a computer numeric control (CNC) machine. The proposed solution is to use deep learning with reinforcement to map the performance of the Reference Points Realization Optimization (RPRO) algorithm used in industry. A detailed study was conducted to see how well the proposed method performs the targeted task. In addition, the influence of a number of different factors and hyperparameters of the learning process on the performance of the trained agent was investigated. The proposed solution achieved very good results, not only satisfactorily replicating the performance of the benchmark algorithm, but also, speeding up the machining process and providing significantly higher accuracy.
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Authors and Affiliations

Dawid Kalandyk
Bogdan Kwiatkowski
ORCID: ORCID
Damian Mazur
ORCID: ORCID
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Abstract

The paper presents an off-line application that determines the maximum accuracy of the reference points for the given dynamics parameters of a CNC machine. These parameters are maximum speed, acceleration, and JERK. The JERK parameter determines the rate of change of acceleration. These parameters are defined for each working axis of the machine. The main achievement of the algorithm proposed in the article is the determination of the smallest error specified for each reference point resulting from the implemented G-code for the considered dynamic parameters of the CNC machine. The solutions to this problem in industry consider the improvement in the accuracy of hitting the reference points, but they do not provide information on whether the obtained solution is optimal for such parameters of the machine dynamics. The algorithm makes the accuracy dependent on the adopted dynamic parameters of the machine and the parameters of the PLC controller used in the CNC machine.
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Authors and Affiliations

Bogdan Kwiatkowski
1
ORCID: ORCID
Tadeusz Kwater
2
ORCID: ORCID
Damian Mazur
1
ORCID: ORCID
Jacek Bartman
3
ORCID: ORCID

  1. Department of Electrical and Computer Engineering Fundamentals, Rzeszow University of Technology, ul. W. Pola 2, 35-959 Rzeszow, Poland
  2. Institute of Technical Engineering, State University of Technology and Economics in Jaroslaw, ul. Czarnieckiego 16, 37-500 Jaroslaw, Poland
  3. University of Rzeszow, ul. Rejtana 16C, Rzeszow, Poland
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Abstract

The paper presents the results of research work on the development of a rapidprototyping test stand for testing: servo control algorithms, trajectory generation, algorithms for increasing overall quality of the feed-drive modules within two axis (X-Y) table of the milling machine. Open architecture interface of the prepared control system lets the potential user test functionality of integration of diagnostic tools within the motion controller - directly, without taking into account communication with top-level CNC system.

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Authors and Affiliations

Krzysztof Pietrusewicz
Michał Bonisławski
Rafał Pajdzik
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Abstract

This paper deals with production of safety inlay for steam locomotive valve by the Patternless Process method. For the moulds creation was used moulding mixtures of II. generation, whereas binder was used a water glass. CNC miller was used for creation of mould cavity. Core was created also by milling into block made of moulding compound. In this article will be presented also making of 3D model, setting of milling tool paths and parameters for milling.

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Authors and Affiliations

R. Pastirčák
D. Urgela
E. Krivoš
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Abstract

Touch-trigger probes for CNC milling machines usually use wireless communication in the radio or IR band. Additionally they enable triggering signal filtering in order to avoid false triggers of the probe. These solutions cause a delay in trigger signal transmission from the probe to the machine tool controller. This delay creates an additional pre-travel component, which is directly proportional to the measurement speed and which is the cause of a previously observed but not explained increase of the pre-travel with the increase of the measurement speed. In the paper, a method of testing the delay time of triggering signal is described, an example of delay time testing results is presented and the previous, unexplained results of other researchers are analysed in terms of signal transmission delay.
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Authors and Affiliations

Michał Jankowski
Adam Woźniak
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Abstract

In the era of Industry 4.0, the automation of processes in the life cycle of a product seems

to be a necessity. Although programming CNC machines with CAM systems make it possible,

it is necessary to effectively acquire knowledge about the programming process and

technological requirements for effective automation. The paper presents a method for decomposition

of knowledge about the CNC machine programming process based on acquiring

knowledge from various sources, both from technologists as well as on the basis of analysis

of archival CNC control programs. To decompose the programming process, it is proposed

to apply the knowledge model described by various attributes. Verification of the method

is shown in the process of knowledge decomposition for manufacturing special production

tooling.

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Authors and Affiliations

Maciej Kowalski
Przemysław Zawadzki
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Abstract

Thermal error always exists in a machine tool and accounts for a large part of the total error in the machine. Thermal displacement in X-axis on a CNC lathe is controlled based on a rapid heating system. Positive Temperature Coefficient (PTC) heating plates are installed on the X-axis of the machine. A control temperature system is constructed for rapid heating which further helps the thermal displacement to quickly reach stability. The system then continuously maintains stable compensation of the thermal error. The presented rapid heating technique is simpler than the compensation of machine thermal errors by interference in the numerical control system. Results show that the steady state of the thermal displacement in the X-axis can be acquired in a shorter time. In addition, almost all thermal errors in constant and varying working conditions could be significantly reduced, by above 80% and 60%, respectively, compared to those without using the rapid heating. Therefore, the proposed method has a high potential for application on the CNC lathe machine for improving its precision.
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Bibliography

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[3] H. Wang, F. Li, Y. Cai, Y. Liu, and Y. Yang. Experimental and theoretical analysis of ball screw under thermal effect. Tribology International, 152:106503, 2020. doi: 10.1016/j.triboint.2020.106503.
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[14] J. Zapłata and M. Pajor. Piecewise compensation of thermal errors of a ball screw driven CNC axis. Precision Engineering, 60:160–166, 2019. doi: 10.1016/j.precisioneng.2019.07.011.
[15] W. Feng, Z. Li, Q. Gu, and J. Yang. Thermally induced positioning error modelling and compensation based on thermal characteristic analysis. International Journal of Machine Tools and Manufacture, 93:26–36, 2015. doi: 10.1016/j.ijmachtools.2015.03.006.
[16] H. Zhou, P. Hu, H. Tan, J. Chen, and G. Liu. Modelling and compensation of thermal deformation for machine tool based on the real-time data of the CNC system. Procedia Manufacturing, 26:1137–1146, 2018. doi: 10.1016/j.promfg.2018.07.150.
[17] A.A. Kendoush. An approximate solution of the convective heat transfer from an isothermal rotating cylinder. International Journal of Heat and Fluid Flow, 17(4):439–441, 1996. doi: 10.1016/0142-727X(95)00002-8.
[18] T.L. Bergman, F.P. Incropera, D.P. DeWitt, and A.S. Lavine. Fundamentals of Heat and Mass Transfer. 7th edition, John Wiley & Sons, 2011.
[19] Z. Li, K. Fan, J. Yang, and Y. Zhang. Time-varying positioning error modeling and compensation for ball screw systems based on simulation and experimental analysis. The International Journal of Advanced Manufacturing Technology, 73:773–782, 2014. doi: 10.1007/s00170-014-5865-9.
[20] J.G. Yang, Y.Q. Ren, and Z.C. Du. An application of real-time error compensation on an NC twin-spindle lathe. Journal of Materials Processing Technology, 129(1-3):474–479, 2002. doi: 10.1016/S0924-0136(02)00618-0.
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Authors and Affiliations

Van-The Than
1
ORCID: ORCID
Chi-Chang Wang
2
Thi-Thao Ngo
1
Guan-Liang Guo
2

  1. Faculty of Mechanical Engineering, Hung Yen University of Technology and Education, Khoai Chau District, Hung Yen Province, Vietnam
  2. Department of Mechanical and Computer-Adided Engineering, Feng Chia University, Taichung, Taiwan, R.O.C.
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Abstract

This paper reports on efficient experimental and numerical techniques used in the design of critical infrastructure requiring special protection measures regarding security and safety. The presented results, some of which have already been reported in [1], were obtained from perforation experiments carried out on S235 steel sheets subjected to impacts characterized as moderate velocity (approximately 40–120 m/s). The metal was tested using the Hopkinson Bar Technique and pneumatic gun. The originality of perforation testing consist on using a thermal chamber designed to carry out experiments at higher temperatures. 3D scanners and numerically controlled measuring devices were used for the final shape deformation measurements. Finally, the results of FEM analysis obtained using explicit solver are presented. The full-scale CAD model was used in numeric calculations.
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Bibliography


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Authors and Affiliations

Maciej Klosak
1
ORCID: ORCID
Michał Grazka
2
ORCID: ORCID
Leopold Kruszka
3
ORCID: ORCID
Wojciech Mocko
4
ORCID: ORCID

  1. Universiapolis, Technical University of Agadir, Technopole d'Agadir, Qr Tilila, 80000 Agadir, Morocco
  2. Military University of Technology, Faculty of Mechatronics, Armaments and Aviation, ul. gen. Sylwestra Kaliskiego 2, 00-908 Warsaw, Poland
  3. Military University of Technology, Faculty of Civil Engineering and Geodesy, ul. gen. Sylwestra Kaliskiego 2, 00-908 Warsaw, Poland
  4. Motor Transport Institute, Center for Material Testing, Jagiellońska 80, 03-301 Warsaw, Poland
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Abstract

The machining accuracy of CNC machine tools is significantly affected by the thermal deformation of the feed system. The ball screw feed system is extensively used as a transmission component in precise CNC machine tools, responsible for converting rotational motion into linear motion or converting torque into repetitive axial force. This study presents a multi-physical coupling analysis model for the ball screw feed system, considering internal thermal generation, intending to reduce the influence of screw-induced thermal deformation on machining accuracy. This model utilizes the Fourier thermal conduction law and the principle of energy conservation. By performing calculations, the thermal source and thermal transfer coefficient of the ball screw feed system are determined. Moreover, the thermal characteristics of the ball screw feed system are effectively analyzed through the utilization of finite element analysis. To validate the proposed analysis model for the ball screw feed system, a dedicated test platform is designed and constructed specifically to investigate the thermal characteristics of the ball screw feed system in CNC machine tools. By selecting specific CNC machine tools as the subjects of investigation, a comprehensive study is conducted on the thermal characteristics of the ball screw feed system. The analysis entails evaluating parameters like temperature field distribution, thermal deformation, thermal stress, and thermal equilibrium state of the ball screw feed system. By comparing the simulation results from the analysis model with the experimental test results, the study yields the following findings: The maximum absolute error between the simulated and experimental temperatures at each measuring point of the feed system components is 2.4◦C, with a maximum relative error of 8.7%. The maximum absolute error between the simulated and experimental temperatures at the measuring point on the lead screw is 2.0◦C, with a maximum relative error of 6.8%. The thermal characteristics obtained from the steady-state thermal analysis model of the feed system exhibit a prominent level of agreement with the experimental results. The research outcomes presented in this paper provide valuable insights for the development of ball screw feed systems and offer guidance for the thermal design of machine tools.
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Authors and Affiliations

Junjian Zheng
1
ORCID: ORCID
Xiaolei Deng
2
Junshou Yang
2
Wanjun Zhang
2
Xiaoliang Lin
2
Shaofei Jiang
1
Xinhua Yao
3
Hongchen Shen
3

  1. College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China
  2. Key Laboratory of Air-driven Equipment Technology of Zhejiang Province, Quzhou University, Quzhou 324000, China
  3. School of Mechanical Engineering, Key Laboratory of 3D Printing Process and Equipment of Zhejiang Province, State Key Laboratory of FluidPower and Mechatronic Systems, Zhejiang University, Hangzhou 310027, China

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