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1
EN
Optimization of industrial processes such as manufacturing or processing of specific materials constitutes 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 the 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.
EN
Purpose: This article focuses on a comparative analysis of the technology of additive shaping and multi-axis CNC machining. The authors examine the impact of 3D printing assumptions and CNC machining conditions on the strength of the selected PET material used to produce machine elements on the example of a shaft-type element. The purpose of the study is to identify a better production method. Design/methodology/approach: The analysis was carried out by producing six samples of different diameters and lengths from the same thermoplastic material (ethylene terephthalate) by both 3D printing (FDM) and CNC machining. The resulting samples were subjected to a static compression test, for which a universal testing machine by Zwick & Roell 100 kN was used. The following factors during the production of elements were compared: the difficulty of preparing the project, the time of execution, the cost of execution, the accuracy of the execution and the properties of the elements made. Findings: Elements made by CNC machining have higher compressive strength and yield strength, as well as lower relative expansion and relative shortening. Those produced by CNC machining are created as a monolith (semi-finished product), and the printed elements are incrementally shaped layer by layer. During the strength test, the spaces between the layers decrease, which in turn causes an increase in relative shortening and a decrease in strength properties. Research limitations/implications: Further research is planned on the analysis of manufacturing technology using incremental shaping technology (e.g. change of filling density, change of filling type, change of material) compared to CNC machining. Practical implications: In the conducted tests, a universal method was used, which can be translated into a comparative study of elements made of other materials. Originality/value: The research carried out allowed for the initial assessment of the use of PET material for the production of machine elements through 3D printing and CNC machining.
3
EN
The subject of microbiological tests of coolants presented in the work is the cutting fluid (emulsifying oil) of Fuchs ECOCOOL 68 CF3. The liquid was taken from the tanks of three different numerically controlled machines (Lasertec 65, MillTap 700, CTX beta 1250 TC), used with different intensity. The five most characteristic and popular media were used in the study: nutrient agar - plain, TSA medium (tryptone-soy-agar), medium with dichloran, rose bengal and chloramphenicol, Sabouraud agar with Chloramphenicol, Czapka agar. The incubation time was dependent on the type of microorganisms. After the specified time, the plates inoculated on the medium were subjected to visual observations and under the Leica DM 500 microscope. As a result of the observation, the following types of microorganisms (fungi and bacteria) were detected: Aspergillus Niger Tiegh, Candida Albicans, Saphylococcus Aureus, Micrococcus Luteus and Escherchia Coli and Citrobacter Freundia. The assessments were made in fixed periods. The results are presented as a function of the intensity of the use of cutting fluids. Microbiological analysis of machining fluids will allow for optimizing the time periods of using coolants and will also contribute to the protection of the operator's health and indirectly "extending the life cycle" of the technological machine.
EN
This paper addresses Acoustic Emission (AE) from Computer Numerical Control (CNC) machining operations. Experimental measurements are performed on the CNC lathe sensors to provide the power consumption data. To this end, a hybrid methodology based on the integration of an Artificial Neural Network (ANN) and a Shuffled Frog-Leaping Algorithm (SFLA) is applied to the data resulting from these measurements for data fusion from the sensors which is called SFLA-ANN. The initial weights of ANN are selected using SFLA. The goal is to assess the potency of the signal periodic component among these sensors. The efficiency of the proposed SFLA-ANN method is analyzed compared to hybrid methodologies of Simulated Annealing (SA) algorithm and ANN (SA-ANN) and Genetic Algorithm (GA) and ANN (GA-ANN).
PL
Przedstawiono nową koncepcję hybrydowego kształtowania złożonych wyrobów, bazującą na integracji techniki przyrostowej oraz wykańczającej obróbki ubytkowej na jednej obrabiarce CNC. Ta koncepcja jest intensywnie rozwijana w ramach strategii Produkcja/Wytwarzanie 4.0. Podano zasady i możliwości technologiczne integracji laserowego napawania proszkowego i wykańczającego toczenia/frezowania w różnych zastosowaniach przemysłowych, takich jak: kształtowanie przyrostowe dodatkowych elementów w złożonych geometrycznie wyrobach, nanoszenie warstw funkcjonalnych oraz naprawa zużytych lub uszkodzonych, dużych i drogich elementów, np. łopatek i obudów turbin lotniczych. Omówiono stosowane strategie technologiczne, programy CAD/CAM i rozwiązania konstrukcyjne obrabiarek hybrydowych CNC.
EN
This review paper highlights the hybrid manufacturing processes which integrate the additive and subtractive processes performing on one hybrid platform consisting of the LMD (laser metal deposition) unit and multi-axis CNC machining center. This hybrid technology is rapidly developed and has many applications in Production/Manufacturing 4.0 including the LRT (laser repair technology). In particular, some important rules and advantages as well as technological potentials of the integration of a powder metal deposition and finishing CNC milling/turning operations are discussed and overviewed. Some representative examples such as formation of difficult features around the part periphery, deposition of functional layers and coatings and repair of high-value parts in aerospace industry are provided. Moreover, the technological strategies, CAD/CAM and CAI programs and construction designs of the hybrid manufacturing platforms are explained. Some conclusions and future trends in the implementation of hybrid processes are outlined.
EN
This review paper highlights the hybrid manufacturing processes which integrate the additive and subtractive processes performing on one hybrid platform consisting of the LMD (laser metal deposition) unit and CNC machine tools. In particular, some important rules and advantages as well as technological potentials of the integration of different AM technique and finishing CNC machining operations are discussed and overviewed. Some representative examples such as formation of difficult features around the part periphery, deposition of functional layers and coatings and repair of high-value parts in aerospace industry are provided. Some conclusions and future trends in the implementation of hybrid processes are outlined.
7
Content available Experimental diagnostic research of fixture
EN
In the article the experimental research of the flexible fixture is shown, which provides sufficient accessibility and allows to perform multiaxis machining of parts, e.g. of levers with one setup. The experimental studies compared with the results of numerical simulation that were previously obtained, confirmed that the proposed fixture design meets all accuracy parameters. The results of experimental studies on the determination of displacements have shown that the values of displacements, determined statically, in the proposed fixtures are smaller than the dedicated ones. The analysis of the data of determination of the frequencies of the proper oscillations in the machining of the levers from steel and cast iron has confirmed that the first critical frequency of the fixture significantly exceeds the similar parameter of dedicated fixture.
PL
Porównywano zastosowania dostępnych technik programowania obróbki numerycznej przedmiotów o powtarzających się elementach konstrukcji. Analizowano możliwości stosowania programowania parametrycznego w trybie programowania zorientowanego warsztatowo oraz pracy w środowisku systemu klasy CAM. Zwrócono uwagę na przejrzystość tworzonego programu w aspekcie możliwości jego edycji i korekty składni, formy zapisu programu w pamięci obrabiarki oraz czasochłonność realizacji przykładowej operacji obróbki.
EN
The application of available methods to NC programming for parts with replicate geometrical elements is comparatively analysed. The possibility for the use of parametric programming both in workshop operation mode and in the environment of CAM system were presented. The capability of editing generated program and syntax correction, the form of its input into machine memory as well as exemplary part program execution time are studied.
9
Content available remote Przygotowanie procesu produkcyjnego formy wtryskowej
PL
Omówiono sposób przygotowania procesu produkcyjnego formy wtryskowej na element wchodzący w skład mechanizmu, jakim jest wózek dziecięcy. Przedstawiono strategię opracowania planu obróbczego oraz przygotowania kodu sterującego na obrabiarki sterowane numerycznie. Zaprezentowano metodę obróbki elementów kształtujących, z których złożona jest forma, na 5-osiowym centrum frezerskim Matsuura MX-520.
EN
Describes a process for the preparation of the production process of the injection mold for the component of the mechanism, which is the stroller. It outlines the strategy for the development of a processing plan and prepare the control code for numerically controlled machines. Presented method of processing elements shaping, which is a form of complex 5-axis center of a milling Matsuura MX-520.
10
Content available Production of castings by patternless process
EN
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.
11
Content available remote Device for production of prototype moulds by milling
EN
This paper deals with a new mode of production of prototype castings by the method of Patternless Process and a device for production of moulds used in the method of patternless process. The principle of the Patternless Process method consists in creating a 3D model in the CAD system and subsequent milling to form a casting from the block of moulding sands without using of pattern equipment by using a CNC machine tool. This method markedly reduces the time needed to produce the casting, because this method does not need the production of pattern. The paper deals with selecting a machine for production of prototype castings by Patternless Proccess and a detailed description of a device to be used for making moulds. The paper describes in detail the design of the device and individual components needed in the construction of the machine.
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