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Design Optimization of Compliant Mechanisms for Vibration- Assisted Machining Applications Using a Hybrid Six Sigma, RSM-FEM, and NSGA-II Approach 基于混合六西格玛、RSM-FEM和NSGA-II方法的振动辅助加工柔顺机构设计优化
Q2 Engineering Pub Date : 2023-05-28 DOI: 10.36897/jme/166500
Huy Pham, Van-Khien Nguyen, Quang-Khoa Dang, Thi Van Anh Duong, Duc-Thong Nguyen, Thanh-Vu Phan
APPROACH Vibration-assisted machining, a hybrid processing method, has been gaining considerable interest recently due to its advantages, such as increasing material removal rate, enhancing surface quality, reducing cutting forces and tool wear, improving tool life, or minimizing burr formation. Special equipment must be designed to integrate the additional vibration energy into the traditional system to exploit those spectacular characteristics. This paper proposes the design of a new 2-DOF high-precision compliant positioning mechanism using an optimization process combining the response surface method, finite element method, and Six Sigma analysis into a multi-objective genetic algorithm. The TOPSIS method is also used to select the best solution from the Pareto solution set. The optimum design was fabricated to assess its performance in a vibration-assisted milling experiment concerning surface roughness criteria. The results demonstrate significant enhancement in both the manufacturing criteria of surface quality and the design approach criteria since it eliminates modelling errors associated with analytical approaches during the synthesis and analysis of compliant mechanisms.
APPROACH振动辅助加工是一种混合加工方法,由于其提高材料去除率、提高表面质量、减少切削力和刀具磨损、提高刀具寿命或最大限度地减少毛刺形成等优点,近年来引起了人们的极大兴趣。必须设计特殊设备,将额外的振动能量集成到传统系统中,以利用这些壮观的特性。本文提出了一种新的2自由度高精度柔顺定位机构的设计,该机构采用了将响应面法、有限元法和六西格玛分析结合为多目标遗传算法的优化过程。TOPSIS方法也用于从Pareto解集中选择最佳解。制作了最佳设计,以评估其在振动辅助铣削实验中的性能,该实验涉及表面粗糙度标准。结果表明,表面质量的制造标准和设计方法标准都得到了显著提高,因为它消除了柔顺机构综合和分析过程中与分析方法相关的建模误差。
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引用次数: 0
Towards Sustainable and Intelligent Machining: Energy Footprint and Tool Condition Monitoring for Media-Assisted Processes 迈向可持续和智能加工:介质辅助加工的能源足迹和刀具状态监测
Q2 Engineering Pub Date : 2023-05-24 DOI: 10.36897/jme/166463
H. Dogan, Llyr Jones, S. Hall, A. Shokrani
Reducing energy consumption is a necessity towards achieving the goal of net-zero manufacturing. In this paper, the overall energy footprint of machining Ti-6Al-4V using various cooling/lubrication methods is investigated taking the embodied energy of cutting tools and cutting fluids into account. Previous studies concentrated on reducing the energy consumption associated with the machine tool and cutting fluids. However, the investigations in this study show the significance of the embodied energy of cutting tool. New cooling/lubrication methods such as WS 2 -oil suspension can reduce the energy footprint of machining through extending tool life. Cutting tools are commonly replaced early before reaching their end of useful life to prevent damage to the workpiece, effectively wasting a portion of the embodied energy in cutting tools. A deep learning method is trained and validated to identify when a tool change is required based on sensor signals from a wireless sensory toolholder. The results indicated that the network is capable of classifying over 90% of the tools correctly. This enables capitalising on the entirety of a tool’s useful life before replacing the tool and thus reducing the overall energy footprint of machining processes
减少能源消耗是实现净零制造目标的必要条件。在考虑刀具和切削液蕴含能量的情况下,研究了不同冷却/润滑方式加工Ti-6Al-4V合金的总能量足迹。以前的研究集中在降低与机床和切削液相关的能耗上。然而,本研究的研究表明了刀具蕴含能的重要性。新的冷却/润滑方法,如ws2 -油悬浮,可以通过延长刀具寿命来减少加工的能源足迹。通常在刀具使用寿命结束之前就更换刀具,以防止对工件的损坏,有效地浪费了刀具的一部分蕴含能量。通过训练和验证深度学习方法,可以根据来自无线传感刀架的传感器信号识别何时需要更换工具。结果表明,该网络能够对90%以上的工具进行正确分类。这使得在更换刀具之前充分利用刀具的整个使用寿命,从而减少加工过程的总体能源足迹
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引用次数: 0
Avoidance of Drill Cap Formation in CFRP-Titanium Stack Materials by Using Vibration Assisted Drilling with Defined Coupling of the Oscillation 利用具有确定振荡耦合的振动辅助钻孔避免CFRP钛堆叠材料中的钻头帽形成
Q2 Engineering Pub Date : 2023-05-22 DOI: 10.36897/jme/166274
S. Krall, Markus Prießnitz, C. Baumann, Peter Brandt, F. Bleicher
Drilling of rivet holes in stacked materials consisting of CFRP and Ti-6Al-4V still represents unique challenges. It is common practice to drill the material layers using one single tool. When exiting the final metallic layer, formation of a drill cap usually leads to undesirable burrs and debris, requiring manual post-processing. In this work, a drilling process to avoid drill caps is presented. This is realized using low frequency high amplitude vibration assisted drilling with defined coupling of the rotational speed and the axial oscillations. Drilling parameters and their impact on the quality of the drilled hole in the metallic layer are also investigated. It is found that drill tip geometries and process parameters need to be tuned together to achieve a stable and repeatable process for drill cap avoidance. A highly sensorized experimental setup with multi-sensor systems including high-speed and thermal imaging was used for process evaluation.
在由CFRP和Ti-6Al-4V组成的堆叠材料中钻铆钉孔仍然是一个独特的挑战。通常的做法是使用一个工具钻材料层。当退出最终金属层时,钻帽的形成通常会导致不希望的毛刺和碎屑,需要人工后处理。在这项工作中,提出了一种避免钻帽的钻井工艺。这是通过低频高振幅振动辅助钻井实现的,并定义了转速和轴向振荡的耦合。研究了钻孔参数对金属层钻孔质量的影响。研究发现,为了避免钻帽,需要同时调整钻头的几何形状和工艺参数,以实现稳定和可重复的过程。一个高度敏感的实验装置与多传感器系统,包括高速和热成像被用于过程评估。
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引用次数: 0
Enabling of Automatically Generation of Cutting Paths for Three-Dimensional Pre-Contouring with Waterjet Trimming 水射流切边三维预轮廓切割路径的自动生成
Q2 Engineering Pub Date : 2023-05-17 DOI: 10.36897/jme/166095
Waldemar Reder, E. Uhlmann
Abrasive Water Injector Jet Cutting (AWIJC) is a flexible machining process for manufacturing high-performance materials, such as titan- and nickel-base-alloys. Due to the low ductility and thermal conductivity of these materials, conventional machining is struggling with high tool costs and wear. The tool wear in AWIJC is independent of the machined material, and the process has the potential to provide a cost-efficient solution in machining high-performance materials. Trimming, a near-net-shape pre-contouring with multi-stage AWIJC, requires a detailed knowledge of cutting paths for all steps in advance. In order to enable a geometrical flexible manufacturing process, an automatically cutting path generation is necessary. This article presents an application developed with NX Open using Visual Basic. The application TrimCAD is able to provide all necessary geometries for trimming based on the geometries of initial and finished parts. Furthermore, it is possible to adjust the number of cuts and the degree of pre-contouring. All geometries are automatically exported as a standardized three-dimensional STEP-file. The STEP-geometries can be processed to the CAM-processor of the waterjet machine. TrimCAD is an innovative possibility to machine three-dimensional parts made of high-performance materials.
磨料水喷射切割(AWIJC)是一种灵活的加工工艺,用于制造高性能材料,如泰坦和镍基合金。由于这些材料的低延展性和导热性,传统的加工正在与高刀具成本和磨损作斗争。在AWIJC中,刀具磨损与加工材料无关,该工艺有可能为加工高性能材料提供经济高效的解决方案。修剪,与多阶段AWIJC的近净形状预轮廓,需要提前所有步骤的切割路径的详细知识。为了实现几何柔性制造过程,需要自动生成切削路径。本文介绍了一个使用Visual Basic开发的NX Open应用程序。TrimCAD应用程序能够根据初始和成品零件的几何形状提供所有必要的几何形状。此外,还可以调整切割的数量和预轮廓的程度。所有几何图形都自动导出为标准化的三维step文件。step几何图形可以加工到喷水机的cam处理器上。TrimCAD是一种创新的可能性,可以加工由高性能材料制成的三维零件。
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引用次数: 0
Multi-Objective Optimization for Weld Track Geometry in Wire-Arc Directed Energy Deposition of ER308L Stainless Steel ER308L不锈钢电弧定向能量沉积焊缝轨迹几何的多目标优化
Q2 Engineering Pub Date : 2023-05-15 DOI: 10.36897/jme/166134
V. C. Nguyen, V. Le, N. Pham, Anh-Thang Nguyen
In this research, the weld track geometry in wire-arc DED (directed energy deposition) of ER308L stainless steel was predicted and optimized. The studied geometrical attributes of weld tracks include weld track width ( WTW ), weld track height ( WTH ), and contact angle ( α ). The experiment was designed based on Taguchi method with three variables (current I , voltage U , and weld velocity v ) and four levels for each variable. The ANOVA was adopted to evaluate the accuracy of the models and impact levels of variables on the responses. The TOPSIS method was utilized to predict the optimal variables. The results indicated that the predicted models were built with high accuracy levels ( R 2 = 98.92%, 98.77%, and 98.91% for WTW , WTH , and α , respectively). Among the studied variables, U features the highest effects on WTW and  with 78.56% and 69.90% of contribution, respectively, while v is the variable that has the most impact on WTH with 39.82% of contribution. The optimal variables predicted by TOPSIS were U = 23 V, I = 140 A, and v = 300 mm/min, which allows building components with stable and regular geometry.
在本研究中,对ER308L不锈钢丝弧DED(定向能沉积)中的焊缝轨迹几何形状进行了预测和优化。研究的焊缝几何属性包括焊缝宽度(WTW)、焊缝高度(WTH)和接触角(α)。实验基于田口方法设计,有三个变量(电流I、电压U和焊接速度v),每个变量有四个水平。采用方差分析来评估模型的准确性和变量对反应的影响水平。采用TOPSIS方法对最优变量进行预测。结果表明,建立的预测模型具有较高的准确度(WTW、WTH和α的R2分别为98.92%、98.77%和98.91%)。在所研究的变量中,U对WTW和 贡献率分别为78.56%和69.90%,而v是对WTH影响最大的变量,贡献率为39.82%。TOPSIS预测的最佳变量为U=23 V,I=140 A,V=300 mm/min,这使得建筑构件具有稳定和规则的几何形状。
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引用次数: 0
The Optimization of Micro-Edm Machining Process when Using Carbon Coated Micro Electrode as a Tool 碳涂层微电极刀具微细电火花加工工艺的优化
Q2 Engineering Pub Date : 2023-05-07 DOI: 10.36897/jme/165929
Bich Mac, S. Shirguppikar, V. Ganachari
The amount of electrode wear in micro-EDM has a direct effect on the dimensional accuracy of the machined hole. Therefore, improving the corrosion resistance of electrodes in micro-EDM is still of great interest. The effective coating of thin film for the micro tool electrodes in the case of micro-EDM can lead to minimize the electrode wear which eventually improve the productivity and machining quality. In the present study, experiments were performed on micro-EDM using carbon coated tool electrode and optimized using Taguchi-Topsis to investigate optimum levels of Depth of cut ( Z ) and overcut ( OVC ). It was concluded that optimum conditions had improved significantly using carbon coated micro tool electrode. Optimal levels of technological parameters include V = 160 V, C = 10000 pF, RPM = 600 rpm, and Z opt = 2.525 mm, OVC opt = 65.257  m. The quality of the machined surface with the coated electrode at optimal conditions is analysed and evaluated. The Topsis method is a suitable solution to this problem, and the steps to perform the calculation in this technique are simple.
微细电火花加工中电极的磨损量直接影响加工孔的尺寸精度。因此,提高微细电火花加工中电极的耐腐蚀性仍然是人们关注的焦点。在微细电火花加工的情况下,为微细工具电极有效地涂覆薄膜可以最大限度地减少电极磨损,从而最终提高生产率和加工质量。在本研究中,使用碳涂层工具电极对微细电火花加工进行了实验,并使用田口Topsis进行了优化,以研究最佳切割深度(Z)和过切割(OVC)水平。结果表明,使用碳涂层微工具电极,优化条件得到了显著改善。工艺参数的最佳水平包括V=160 V,C=10000 pF,RPM=600 RPM,Z opt=2.525 mm,OVC opt=65.257 m.分析和评估在最佳条件下具有涂层电极的机械加工表面的质量。Topsis方法是解决这个问题的合适方法,并且在该技术中执行计算的步骤很简单。
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引用次数: 0
Autonomous Assembly and Disassembly - Key Technologies and Links for the Adaptive Self-Optimization of Future Circular Production 自主拆装——未来循环生产自适应优化的关键技术与环节
Q2 Engineering Pub Date : 2023-04-28 DOI: 10.36897/jme/163522
S. Ihlenfeldt, Marcel Lorenz, U. Frieß, Rayk Fritzsche
European industry and beyond, faces the challenge of becoming carbon neutral within an unprecedented short timeframe. An important approach to achieve this goal is the transformation of the current economy to a circular economy. In this context, the reuse of technical products as well as their recycling are in the foreground. Flexibility and adaptability are crucial for the competitiveness of companies. Therefore, adaptive and autonomous assembly and disassembly systems are the key. Classically automated assembly systems are inflexible due to a mostly rigid and predefined sequence control and are mostly strongly oriented towards economic criteria. Existing autonomous production cells, with their focus on autonomy and failure-free operation, also reach their limits in terms of adaptivity. For this reason, intelligent systems are needed that are able to act autonomously and without interference, as well as to cope with complex and cognitively demanding situations and tasks.
欧洲工业和其他行业面临着在前所未有的短时间内实现碳中和的挑战。实现这一目标的一个重要途径是将当前经济转变为循环经济。在这种背景下,技术产品的再利用和回收利用是很重要的。灵活性和适应性对企业的竞争力至关重要。因此,自适应和自主的拆装系统是关键。传统的自动化装配系统是不灵活的,因为大多是刚性和预定义的顺序控制,并且大多强烈地面向经济标准。现有的自主生产单元注重自主性和无故障运行,在适应性方面也达到了极限。因此,需要能够自主行动且不受干扰的智能系统,以及能够应对复杂和认知要求高的情况和任务的智能系统。
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引用次数: 0
Development of a neural network structure for identifying begin-end points in the assembly process 装配过程中起止点识别的神经网络结构
Q2 Engineering Pub Date : 2023-04-19 DOI: 10.36897/jme/163318
I. Kutschenreiter-Praszkiewicz
The paper presents an approach to video-based assembly analysis using machine learning. A neural network is one of the machine learning methods that is widely studied in many engineering fields. The purpose of this paper is to develop a deep neural network structure for identifying begin-end points for a selected component assembly process. A neural network structure that effectively identifies begin-end points is proposed and an example from industry is presented. The proposed approach can prove useful in the assembly process analysis.
本文提出了一种使用机器学习进行基于视频的装配分析的方法。神经网络是在许多工程领域中广泛研究的机器学习方法之一。本文的目的是开发一种深度神经网络结构,用于识别选定零部件装配过程的起点和终点。提出了一种有效识别起点-终点的神经网络结构,并给出了一个工业实例。该方法可用于装配过程分析。
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引用次数: 0
Design and Optimization of a Cross-Beam Force Transducer for a Stationary Dynamometer for Measuring Milling Cutting Force 用于铣削切削力测量的固定式测力仪横梁力传感器的设计与优化
Q2 Engineering Pub Date : 2023-03-24 DOI: 10.36897/jme/162514
Muhammad Rizal, Jaharah A. Ghani, H. Usman, M. Dirhamsyah, Amir Zaki Mubarak
This paper’s objective is to design and optimize a force transducer to build a stationary dynamometer that can measure three axes of milling cutting force. To reduce interference error and increase sensitivity, the force transducer's Maltese cross-beam design was optimized. The force transducer's performance depends on three design parameters: the cross-rectangular beam's through-hole length and width, the compliant plate thickness, and the strain, stress, and stiffness of force transducer constructions calculated by ANSYS. The response surface method (RSM) estimates a desired second-order polynomial function for three geometric parameters based on sensitivity, interference error, safety factor, and stiffness. A stationary dynamometer prototype was made with four optimized force transducers and several piezoresistive strain sensors. The developed dynamometer has good linearity, repeatability, and hysteresis, as well as high sensitivities and low cross-sensitivity errors. The reference dynamometer's cutting force measurements were very close to those of the designed dynamometer in the validation test.
本文的目的是设计和优化一种力传感器,以建立一个可以测量三轴铣削切削力的固定式测力仪。为了减小干扰误差,提高灵敏度,对力传感器的马尔氏横梁进行了优化设计。力传感器的性能取决于三个设计参数:交叉矩形梁的通孔长度和宽度、柔性板厚度以及通过ANSYS计算的力传感器结构的应变、应力和刚度。响应面法(RSM)基于灵敏度、干涉误差、安全系数和刚度对三个几何参数进行二阶多项式函数估计。采用四个优化后的力传感器和几个压阻式应变传感器制作了一个固定式测功机样机。所研制的测功机具有良好的线性度、重复性和滞后性,灵敏度高,交叉灵敏度误差小。在验证试验中,参考测功机的切削力测量值与设计测功机的切削力测量值非常接近。
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引用次数: 0
New Trends in Hybrid Finishing Processes of Metallic Additively Fabricated Parts – a Short Review 金属加成型零件混合精加工工艺的新趋势——简评
Q2 Engineering Pub Date : 2023-03-20 DOI: 10.36897/jme/162284
J. Rech, W. Grzesik
This comprehensive survey highlights some important finishing processes used in fabricating additively manufactured parts, mainly using SLM (Selective Laser Melting). In practice, there are applied hybrid processes which integrate additive and subtractive componential processes (AM+SM type) or additional finishing processes, mainly based on the electrochemical polishing such as ECP (Electrochemical Cavitation Polishing) and PEMEC (Electrochemical-Mechanical Polishing) ones. On the other hand, AFM (Abrasive Flow Machining) is predomi-nantly recommended for conformal cooling (CC) channels. Some conclusions and future trends in the implemen-tation of special hybrid finishing processes are outlined.
本文重点介绍了增材制造零件中使用的一些重要的精加工工艺,主要是使用SLM(选择性激光熔化)。在实际应用中,主要以电化学抛光为基础,如ECP(电化学空化抛光)和PEMEC(电化学机械抛光)等,存在着将增、减组分工艺(AM+SM型)或附加精加工工艺相结合的应用混合工艺。另一方面,AFM(磨料流加工)主要被推荐用于共形冷却(CC)通道。概述了特种混合整理工艺实施的一些结论和未来趋势。
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引用次数: 0
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Journal of Machine Engineering
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