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Please follow the links to view the publication.Wireless sensor networks Zigbee applied on sewage treatment station
http://dl-live.theiet.org/content/conferences/10.1049/cp.2012.0598
The good efficiency in a sewage treatment plant (WWTP) is a great importance to the environment. The management of electromechanical equipment installed in these stations is a major challenge due to the fact that they are installed on areas of difficult access and maintenance unhealthy and making the time for the correction of any faults is extended. This paper proposes the development of a Wireless Sensor Network (WSN), in order to monitor electromechanical equipment, allowing the Concessionaire a predictive control in real time. The design of a wireless sensors network for monitoring equipment requires not only the development and assembly of the sensor modules, but must also include the development of software for managing the data collected. Thus, this work includes a Zigbee WSN, small, adapted for monitoring of electromechanical equipment and environmental conditions of a WWTP, type stabilization pond, installed in an area of approximately 0.15 km<sup xmlns="http://pub2web.metastore.ingenta.com/ns/">2</sup> and the average flow of 320 liters of treatment per second. The experimental results show that this monitoring system can perform with the collection of parameters of performance and quality assessment at the station. (5 pages)SCADA approaches to remote condition monitoring
http://dl-live.theiet.org/content/conferences/10.1049/cp.2011.0589
Traditionally, remote monitoring architectures have relied on data loggers collecting data at source for transmission to other systems using either bespoke protocols or ASCII formatted data transfer. As technology evolves, more plant equipment is becoming 'intelligent' and can often report its own condition and health status. Furthermore, many items of plant are becoming network-enabled utilising either fixed or wireless media (in some cases both). These changes are forcing a rethink on strategy how we can best connect to the plant equipment to extract the essential condition information, and how we transport this across data networks into the necessary domains for action and analysis? Coupled with this is the ever increasing pressure from industry to utilise open and standardised protocols, data models and system approaches to reduce cost, allow for future expansion and provide flexibility to interchange system components. By their very nature, SCADA systems deliver more open connectivity options, including standard protocols, allowing end users to pick and choose the right component for their application, ultimately delivering a lower life cycle cost. (6 pages)The application of virtual reality technology in platen die-cutting machine design-manufacturing
http://dl-live.theiet.org/content/conferences/10.1049/cp.2011.1043
The emergence of Virtual Reality Technology provides an effective way to solve problems in the process of traditional product development, and brings the changing of method and conception in production field. The characteristics of Virtual Reality Technology and product development process are expounded. Then the Virtual Reality Technology's necessity and significance as well as the existing key technical problems in post-press processing equipment - die-cutting machine design and manufacture are analyzed. Finally in the foundation of research development and achievements of movement characteristics and elastic dynamics, for example of dual-elbow-bar mechanism, its motion simulation is realized on the basis of the nodes using Eon Studio.Study on automatic feeding in hot stamping production line
http://dl-live.theiet.org/content/conferences/10.1049/cp.2011.1036
The material feeding in hot stamping is quite different from traditional cold stamping. This paper described some key issues of automatic high-temperature steel plate feeding, some analysis and studies were done about gripping method, clamping force, local and whole plate temperature drop in transferring process, and some ideas about robot manipulator' design were proposed with that.The design-manufacturing technology and the trends of the development of full automatic plane die-cutting machine
http://dl-live.theiet.org/content/conferences/10.1049/cp.2011.1032
In recent years, with the rapid development of packaging industry, the request for die-cutting technology and the performance of die-cutting machine is much higher, and it has been paid much more attention by industry. Through the comparison of domestic and international die-cutting technology situation, the differences between them and defects of domestic machine were analyzed from the design method, and the digital design and virtual prototype design were put forward to compensate these shortages. With the survey and analysis of domestic die-cutting machine manufacturing process and technology, taking the key parts processing for example, die-cutting machine manufacturing technology status was expounded, then on the basis of relevant patent technique and market research, development trends of die-cutting equipment and several new problems brought by them were listed.Grinding wheel dressing technology for gear form grinding machine tools
http://dl-live.theiet.org/content/conferences/10.1049/cp.2011.1042
Gear form grinding technology is widely used in the process of gear manufacturing. Grinding wheel dressing is the key technology of gear form grinding process. In this paper, several different grinding wheel dressing methods and the corresponding diamond roller dressing device are simply introduced. The technical parameters of grinding wheel dressing are respectively analyzed, including dressing speed ratio, overlap ratio, dressing depth and axial speed. The experimental tests of gear form grinding are carried out to investigate the effects of dressing parameters on the grinding process. The results of analysis and manufacturing tests can provide the reliable basis for diamond roller dressing in gear form grinding machine tools.Study on lubrication of large-scale numerical control radial-axial direction rolling ring machine
http://dl-live.theiet.org/content/conferences/10.1049/cp.2011.1056
In this article, according to the actual working condition of key friction-pair of numerical control 8000 mm radial- axial direction rolling ring machine, optimization design of the lubricating system was researched. Reasonable lubrication technology schemes were proposed for main transmission box, guide rail, rollers, satisfied the request of heavy load, variable load and high temperature. After system experiments, special lubricants used for numerical control 8000 mm radial-axial direction rolling ring machine were developed.The research on organ printing technology & equipment
http://dl-live.theiet.org/content/conferences/10.1049/cp.2011.1053
Organ printing technology and equipment is integrated innovation of mechanical, control, materials, biological field, which is key development of advanced forming technology in the future. This paper introduce the forming technology of organ printing principle and the performance of the forming device, including motor system, material injection system, cooling system and ultraviolet disinfection components, it provides sterile and clean forming environment for printing experiment. The realization of the organ printing forming technology not only widened the area of manufacturing, but also puts forward new biology and manufacturing technology problem, it can be developed into comprehensive course of biological medicine, advanced manufacturing, tissue engineering, promote the development of biomedicine, integrate biological medicine and advanced manufacturing technology.Fault isolation using self-organizing map (SOM) ANNS
http://dl-live.theiet.org/content/conferences/10.1049/cp.2011.0923
This paper presents a Self-Organizing Map (SOM) Artificial Neural Networks method for fault isolation based on the condition of manufacturing components, equipments and processes. The signals reflecting the conditions of equipment is collected from a set of sensors and processed by signal processing methods, such as filter and de-noising. The features that are extracted in time domain, wavelet domain and wavelet domain are used to train SOM ANNs. After training, the faults are able to be isolated according to the features extracted from the real time information. This approach is very helpful to the maintenance decision- making. A case study shows that SOM ANN can isolate faults correctively and clearly.A universal virtual manufacturing system for cutting machines
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1325
A virtual manufacturing (VM) system plays an important role before machining in reality. The VM systems currently used in CNC field are mainly for typical machine tools, whereas the development of using an industrial robot for cutting task has extended the cutting machine into a more generalized application. However, the current VM system is insufficient to fulfill the demand of different mechanical structures and uniform machine tools and cutting robots. This paper presents a universal 3D simulation system for machine tools and cutting robots with different mechanical structures. All machine tools and cutting robots are synthesized as cutting machines. Robotics methodologies like D-H (Denavit Hartenberg) convention, forward and inverse kinematics; CNC functionalities such as CL-data interpreter, various interpolation manners, are combined as the core of the system. Serial and parallel structured machine tools and cutting robots are simulated as typical case studies. The results show a great uniformity of the system to different mechanical structures.Research of multi-wire saw cutting slurry control system
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1332
This research which is based on the analysis of Multi-Wire Saw Cutting principle relates to slurry flow and temperature control in Multi-Wire Saw Cutting technology. Several relevant experiments were carried out to verify the feasibility of slurry flow control system's application in silicon cutting. According to the conclusion of the research, it is a reliable solution and could significantly improve the cutting quality and accuracy, and also reduce the fluctuation rate. This solution produces high pieces rate and could be applied in real product lines.Modeling of dynamic cutting force in high-speed dry gear based on multifactor coupling
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.0414
The manufacturing industry is demanding more 'green' technology and low impact on our environment. Dry cutting technology, particularly high-speed dry hobbing cutting, as a green manufacturing process can save resources, reduce environmental damage and costs. This paper presents a study on the process optimization of high-speed dry gear milling with a flying cutter. The research takes factors such as the regenerate domino effect of milling librations and non-continuous cutting into account, and establishes a dynamic cutting force model of multifactor coupling for the machining system including machine tool, cutting tool and workpiece. It also carries out digital simulation using Matlab/Simulink to study the vibrational displacement and dynamic milling force in time domain. The models developed were verified through experimental cutting trials. The research showed that proposed models can accurately describe the relationship between the dynamic cutting force and various cutting parameters as well as the state of the tool's librations of multifactor coupling for the system including machine tool, cutting tool and workpiece.Green manufacturing issues in machine tools industry in terms of the life cycle
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.0433
Green Manufacturing (GM) is a kind of sustainable manufacturing mode with the full consideration of resources consumption and environmental impact. Machine tools industry consumes much resource and generates huge environmental emissions, thus it is significant to gathers information about the GM issues in machine tools industry. This study summarizes the key GM issues of the whole life cycle of machine tools product, focusing on machine tools design, manufacturing, and use, and used machine tools remanufacturing. And Information is acquired from the academic literature, visits to industry, as well as through the research and practices by the authors. Based on the key findings from the gathered information, finally, this paper identifies the future directions of GM related areas in machine tools industry.Experimental design and investigation of a screw-pin tooling system for vacuum forming components
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.0416
This paper presented an experimental design and investigation of a screw-pin tooling (SPT) for producing vacuum forming components. The experiments were conducted to evaluate the performance of the machined SPT. Several thermoplastic materials with different sheet thickness were employed to test surface quality of the vacuum formed plastic components based on the machined SPT. From the experimental results, the performance of the machined SPT was discussed. A common problem faced by reconfigurable pin tooling is the dimples on the moulded components. To solve the problem, fillings is applied on the top of the machined screw pins. Several filler materials were selected and tested. The results prove that the machined SPT with the Ronseal high performance wood filler can produce good quality component surfaces.Research on cutting remanufacture deposited materials in the impactive condition
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.0431
Orthogonal experimental were carried for cutting remanufacture deposited Materials in the impactive condition. By the experiments analysis, it can be known that the cutting capability of tools were determind by toughness of tools when the hardness of deposited materials is low. And the hardness of tools becomes the main roles for improving cutting capability when the hardness of deposited materials arrives to HRC56. At the same time, orthogonal design-direct analysis shows that the impact resistant capability of tools does not always means improvement in cutting capability. The comprehensive balance between strength of tools and impacts in the process is favorable method to improve cutting capability of tools.Algorithm of global collision detection for machining freeform surfaces
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1335
The existed algorithms for global collision checking in free form surfaces machining have been analyzed, and a new efficient algorithm is proposed for collision checking in NC machining of freeform surfaces. First, an oblique cube convex hull of the freeform surface is applied to check whether there is intersection between the tool orientation and the oblique cube convex hull. If there is no intersection, it means the tool orientation is feasible. Otherwise, the detailed feasibility checking is developed to detect whether there is a global collision between the freeform surface and the tool orientation. Once there is collision, the tool orientation will be adjusted to avoid the global collision.Problems of shield tunneling for Beijing Metro and solutions
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1105
Based on a detailed investigation and analysis, the present situation of shield tunneling for Beijing metro construction was studied. The main problems of shield method in the planning of the projects were as follows. First, continuous tunnel sections constructed by shield method were only a few; second, the efficiency of shield machine was low; third, the time used for non-driving tasks in shield tunneling was too long; fourth, the construction period using shield tunneling could not be guaranteed; and finally, the additional cost of shield tunneling was high. Detailed analysis indicates that the major cause for the problems was the contradiction of construction time between shield tunnel sections and adjoining stations, with the additional cause being that construction organization of shield tunneling was not well planned, that is the problem of shield machine passing the station was not well solved. A solution to the problems was put forward: let the shield machine pass a series of stations in the line first, and then construct the stations by cut-and-cover method or mining method at proper times. Such scheme shows great advantages in improving the quality, increasing the speed and reducing the cost of metro construction.Development and application of patternless casting mould-manufacturing machine
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1253
Based on the principle and characteristics of patternless casting mould's (core's) manufacturing, CAMTC-SMM1000 CNC machine was developed and widely applied in many shapes of moulds' manufacturing. It's revealed that the patternless casting mould manufacturing technology has a promising application prospect in single piece and small batch of metal parts' manufacturing.Modeling on the drum loading performance of the Helix Shearer based on partial least square regression
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1274
In order to get the accurate and quantificational loading performance model of the Shearer drum, the relevant abbreviated experiment is designed to simulate the drum loading coal process in the different working conditions according to the analogy theory. Select drum's rotated speed, haulage speed and the angle of drum's hub to be variables of the regression model. Experiment data are gotten by the orthogonal method. The regression model is identified by PLSR (Partial Least Square Regression) method to get model's coefficients. The results of the simulation and experiment prove that this kind of method not only can build the model of loading performance correctly and effectively but also have the advantages of fewer experiments, less amount of calculation, stronger ability of the model forecast. The coefficients of the regression model have more actual meaning.Optimization design of gear system in co-rotating twin screw extruder based on Pareto-rank
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1252
According to the structure features of gear system in co-rotating twin screw extruder, the model of the gear system is built, and multi-objective optimization genetic algorithm based on the Pareto-rank is proposed to optimize the parameters of the gear system. The advanced optimal design method for the gear unit in co-rotating twin screw extruder is studied. A typical gear system in co-rotating twin screw extruder is designed, and the results show that the gear system meets the requirements in all aspects. This design method of the gear system is synthetic optimization for the gear system in co-rotating twin screw extruder.Study of soil-blade interaction based on finite element method and classical theory
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1275
In this paper a finite element investigation of the tillage of compacted soil, using the modified Drucker-Prager plasticity material model, was described. The finite element method is adequately contributing to the development of understanding the reality of cutting soil. In most earth moving machinery, the working tool is always a blade. Hence for the tillage systems, accurately predicting the forces between blade and soil is of prime importance in helping to enhance productivity. Parallel computing of the models was fulfilled in HP BL680c G5 server with LS-DYNA 971 MPP software. Three different blade shapes were analyzed by the finite element model. Results show that reverse-rotational rotary tool can work for the cutting of compacted soil. Proper structural parameters of rotary blades can reduce the power consumption. It is perfectly feasible to apply the proposed composite rotary tiller to compacted soil deep-tilling with low power motor. The simulation results were also compared with classical soil mechanics theories for blades (the McKyes approach). A good correlation was obtained between the simulation results and McKyes approach.Dynamic research and optimization design of clamping device for electroslag remelting furnace
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1256
Electroslag Remelting (ESR) technology is a main method of special metallurgy. ESR ingot has high pure, structure dense and favorable mechanical character and becomes high-grade steel and special steel. In this paper, based on virtual machine technology, dynamic research of the working process of electroslag-remelting-furnace clamping device was proceeded; influence of the structure parameters and the motion parameters applied on the motion locus and spring force was researched. 3D solid model of the electroslag remelting furnace was established; mathematical model of the clamping device was established; main technical parameters were accomplished; and simulation research of the dynamic process was proceeded. It was found that, appropriately increasing of damping ratio and spring stiffness of the clamping device is beneficial for lowering overshot and enhancing system stabilization, while sacrificing response speed in some extent.Structural optimization design for high-speed railway bridge erecting machine
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1283
9000kN bridge erecting machine for high-speed railway constructions is used as an object of study in this paper. According to the geometrical structure and features shape of this machine, the characteristic parameters are selected to simplify the structure model. A model of high-speed railway bridge erecting machine is established, using finite element software ANSYS and APDL parametric language. The structural optimization design is studied in the paper, in which the mass of this bridge erecting machine is the optimization objective, and the structural parameters are the design variables. Under the condition of the constraint of the strength and stiffness, the structural parameters are optimized to reduce the mass. After optimazation, the mass of the machine is reduced by 11%. It is shown that this method can short design period, reduce the cost of design and gain accurate result.An analytic method of dynamic modeling on fixed joint interface
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1258
The dynamic characteristics of joint interfaces affect the dynamic behaviors of a whole machine tool structure notably. An analytic method of virtual material hypothesis-based dynamic modeling on fixed joint interface in machine tools was conducted so as to improve the modeling accuracy of whole machine tools. The micro contact part of two contact surfaces in fixed joint interface was assumed as a virtual isotropic material, which is rigidly connected with two components composing fixed joint interface. Considering the interaction between normal and tangential characteristics of fixed interface, a set of analytic solutions of elastic modulus, shear modulus, Poisson ratio and density were deduced from virtual material by adopting Hertz contact theory and fractal theory. By using the finite element structural dynamic modeling approach in existence, when some parameters of material's elastic modulus, Poisson ratio, density, et al. are known, the dynamic model for virtual material composing a component could be established, therefore, the dynamic model for whole structure including joint interface would be obtained.Application of delta HUST-H4 CNC system on crankshaft grinder reformation
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1337
Crankshaft grinder is widely used in shipbuilding, locomotives, large compressors, manufacturing and repair industry, which is used for grinding various large crankshafts and spindle neck parts. HUST-H4 CNC system is a general CNC system developed by Delta-CIMIC (Delta) corporation, which supports maximum 4-axis control and is widely used for CNC lathe, mill, grinders. By using HUST-H4 CNC system, servo drives, servo motors, ball screw & nut fittings, PLC, Marposs P7 measuring instrument and other components, complete the CNC its hardware reformation; designs a highly targeted grinding & wheel dressing interface, targeted programs and machine security procedures. In the practical application, the CNC reformed grinder improves production efficiency greatly, also reduces labor intensity greatly. In additional, by adding anti-collision and ultra-way protection blocks improve the safety performance of the machine.Evaluation method and application for carbon emissions of machine tools based on LCA
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1263
China becomes the largest manufacturing countries and holds the biggest quantity of machine tools. As a typical mechanical products and widely used production equipments, it is necessary to figure out the carbon emissions of machine tools during life cycle. The principle of life cycle assessment (LCA) is introduced to evaluate the carbon emission of machine tool products. The inventory analysis and calculation of carbon emissions during the life cycle stages of raw materials preparation, product manufacture, using and maintenance, transportation are studied and formulated in to equations and data tables. Finally, a case based on a hobbing machine of YB3120A made in China is studied to illustrate and verify the practicality of this method.Numerical simulation technology on tool wear of metal cutting
http://dl-live.theiet.org/content/conferences/10.1049/cp.2010.1294
This paper presents the information on development of study on simulation of tool wear of metal cutting in all over the world. Tool wear in metal cutting on the tool-chip and tool-workpiece interfaces are strongly influenced by the cutting temperature, contact stresses, and relative strains. Finite element method (FEM) is a powerful tool to predict cutting process variables, which are difficult to obtain with experimental methods. The objective of this work is focus on the new development in predicting the tool wear evolution and tool life in orthogonal cutting with FEM simulations.Research on the numerical fitting method of the spiral surface cross-section
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1403
The screw rod is widely used in the oil drilling, chemical industry, light industry and so on. Its machining accuracy affects directly the quality and efficiency of instruments. Thus a deep research on the machining process of the screw rod is urgently needed. The fitting method of the spiral surface cross-section is one of the key issues. It was proposed that cubic spline and parametric cubic spline interpolation function were taken to approximate the spiral surface cross-section by comparing different methods of curve fitting. Coefficients of them were derived, fitting equations were presented and examples were taken to verify the fitting results .At the same time, key issues on the skewness, tangent vectors of ends and so on were involved both in the process of cubic spline and in parametric cubic spline fittings. Corresponding fitting function can be chosen on the basis of foregone data points, so as to provide smooth curves to generate accurate tool path. (4 pages)Study on the acoustic system of the ultrasonic micro milling machine
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1416
In order to machine the small shape of hard and brittle materials, Ultrasonic micro-milling was considered an effective method, especially for the materials' precision machining and ultra-precision machining. Aiming the requirement of micro-machine that it should have small size and high precision, the acoustic system was designed. Modal analysis was used for the designed acoustic system with the soft of finite element analysis. A batch of acoustic systems were made for the experimental testing. The testing result reported that the parameters of the acoustic system for the ultrasonic micro-milling achieve the requirement. (6 pages)Cutting performance and failure characteristic of new cutting tool in dry milling of high-strength steel
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1423
30CrNi3MoV high-strength steel is a difficult-to-cut material which is extensive used in vehicle and aircraft. The possibility of high efficiency dry milling with cemented carbide added with TaC, NbC and Si<sub xmlns="http://pub2web.metastore.ingenta.com/ns/">3</sub>N<sub xmlns="http://pub2web.metastore.ingenta.com/ns/">4</sub> composite ceramic is discussed based on the analysis of the material mechanical properties. The result of cutting tool wear and life shows that, the cutting tool life of 49 min and 55 min respectively is obtained within the cutting speed range of 118 to 186 m/min. The indices in the cutting tool life expressions of ceramic is bigger than that of cemented carbide, which shows that the composite ceramic is more suitable for the face milling of 30CrNi3MoV high-strength steel in the high speed range. The main wear form is the long irregular wear land in flank face, crater in the middle of the chamfer, as well as sector peeling in rake face and triangular breakage in the corner due to the high cutting temperature and the periodical mechanical shock. (4 pages)Design of database system for high speed machining based on Web
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1479
High-speed machining (HSM) is one of the important aspects of advanced manufacturing technology. It has been developed and is becoming one of the main fields of modern manufacturing. In our country, the research in this field started late; therefore, the actual machining and the experimental research on the machining techniques as well as the cutting parameters of HSM are fewer. The relevant selections of cutting parameters and cutting tools are difficult. This database system is designed by analyzing enterprises' actual HSM process examples, and is composed of seven major modules. The user may input basic parameters and obtains the corresponding HSM parameters. The users also can learn essentials of HSM including purchasing HSM equipment or control system, cutting tools' selection, machining process determination, and so on. And the system can determine the tool-path planning automatically by creating HSM process animation or simulating the high-speed milling. The results demonstrate the system is effective to select cutting parameters. (5 pages)Heater operation optimization in tin bath
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1497
Tin bath is the most important equipment in float glass formation, and the glass quality depends mainly on the temperature control of the glass ribbon. Based on the analysis of tin bath formation technology, a mathematic model is set up in order to investigate the radiative heating effect of SiC heater in the formation process. The view factors are difficult to calculate using the classical method because of the heaters, coolers and other components are sheltered by each other. Therefore, Monte Carlo method is used to calculate the radiation transfer coefficient in which emission, absorption, reflection and other probability models are set up. The motion of rays are tracked in the tin bath and the radiation transfer coefficients between various surfaces are obtained by statistics of large amount of rays' destine. The thermal radiation effect of SiC heater on the glass ribbon is calculated. Lower cost is always the goal of float glass production. Minimum economic loss which combines the glass quality and the electricity input is built up to evaluate the heating effect of SiC heater array. The heaters' surface temperatures are set to be the optimized variables, and they are optimized by Genetic Algorithm (GA). The result accesses to the minimum heater array's energy input while ensuring the glass quality. The heaters at the first row should be priority used, and the heaters close to the center should be set at a higher load. (6 pages)A novel method for fabrication of meso-scale cutting tool
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1414
Based on the electrode finishing technique in electrical discharge machining (EDM), a new method is proposed in the article to fabricate meso-scale cutting tool efficiently. The research on the techniques to attain the minitype cutting tool was based on analyzing the feature of EDM on meso-scale cutting tool. The process of fabrication for minitype cutting tool is determined, and the minitype grooving tools with the characteristic sizes of 70 μm were made of two types of materials. This fabrication method proved to be applicable to high efficiency fabrication of meso-scale cutting tool. The factors affecting precision of meso-scale cutting tool were analyzed, the causes for worse shape precision and surface roughness were described specifically, and the suggestions to improve the machining quality were proposed. (4 pages)Research on theory of reconfigurable for NC machine tool
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1496
Reconfigurable manufacture system is to list as one of key technologies which will first solve in the future manufacturing, this article will mainly solve research on theory of reconfigurable for NC machine tool. Reconfigurable machine tool has many merits that include modularization, integration, custom-made, convertibility and so on. That is the traditional machine tool cannot compare.This article has carried on the analysis from the deep hole components classification and the formed movement craft two aspects to the deep hole components race. The reconfigurable deep hole machine tool was to carry on the modular design based two aspects for the module partition and reconstructable analyze, solved the key technologies the machine tool modulation design. From the machine tool bed module, the head of machine tool module, the cutting tool auxiliary system and the numerical control system four aspects, to design and research on reconfigurable machine tool, solved the difficult design problem which the part reconfigurable designed. Finally uses the ultrasonic wave examination technology, has realized numerical control machine tool element level restructuring. (5 pages)Deformation mechanism analysis on laser brazing CBN gear-honing-tool
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1412
Based on the thermal analysis of laser brazing CBN on the gear-honing-tool, the numerical simulation about thermal deformation on tooth profile has been implemented in the paper. During the laser brazing, the deformation mechanism on the tooth profile of gear-honing-tool from addendum to dedendum meets to buckling mechanism, upsetting mechanism and temperature gradient mechanism in turn. The tooth thickness becomes thicker from dedendum circle to reference circle areas, and the tooth thickness becomes thinner from addendum circle to reference circle areas after brazing. The more near the tooth end is, the greater the deformation is, and there is bending deformation along the tooth width direction. The 3024B equipment of tooth profile and tooth direction measurement is used in measuring tooth profile of gear-honing-tool. It is shown in the measurement results that the deformation on tooth profile is symmetrical along the centre plane of tooth thickness. Generally, the accuracy of gear-honing-tool is up to the precision mustard, and the measurement results are approximately in accordance with the numerical simulation results. (6 pages)Finite element analysis on the rolling-mill housing of the dry-powder-embedded zinc-air battery plate forming equipment
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1462
Rolling mill is the important component of the dry-powder-embedded zinc-air battery plate forming equipment. The analyses of stiffness and strength character of the rolling-mill housing are done with ANSYS10.0 in this paper. After the calculation we got the stress distribution and deformed state of the rolling-mill housing. Comparing with the admissible stress of the material, mill housing can meet the strength standard under the integrative effectiveness of various loads. In this paper, after founded the model with parameter, using the distortion results and allowable stress as inhibit condition, the main dimension as design variable and the minimum of volume as goal function, the rolling-mill housing optimization design has been made. After the optimization, the rolling-mill housing longitudinal amount of deformity reduced 15%, biggest principal stresses reduced by 24.1% and rolling-mill housing volume reduce by 9.13 %. (5 pages)Research on the motion control system of multilayer cloth-cutting machine
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1400
Aiming at high speed and precision, a study on a motion control system of cloth-cutting machine based on the motion control card was carried out. This system's design cutting thickness was 0~30mm after negative pressure. According to the characteristics of the cloth-cutting thickness and the analysis of cutting path, a new cutting method of combining direct-turn cutting and lift-turn cutting was proposed. Using the cutting way, the system set an allowable angle in advance. By comparing the rotation angle in cutting path with the allowable angle, the decision whether the machine needed to lift the knife up and then turned can been made. Comparing with the traditional way of testing the lateral force, the new cutting way simplified the mechanical structure and made the control system more efficient. The structure and functions of the motion control system were also introduced in detail; the algorithm of turn cutting has got full descriptions here, providing with the program of turn cutting and the control flow. The test results of the prototype verify the effectiveness of the motion control system. The system achieves the requirements of design accuracy and speed. (5 pages)Dynamics characteristic study of the visco-elastic suspension system of construction vehicles
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1508
Due to the environmental protection laws and regulations being strict day by day now, how to resolve the problems of serious vibration and impact construction vehicles, the poor driving comfortableness and the noise pollution occurring in the vehicles, have become a new urgent task, which affects the development of the heavy duty construction vehicles. The new visco-elastic suspension can not only buffer serious vibration and impact, but also dissipate most of vibration and impact energy into heat, which improves the driving and working condition of the vehicle. However, because of the complex structure of viscoelastic suspensions used in construction vehicles, it is considerable difficult to make model and analyse the characteristics of parameters. In the paper, the semi-car model of tracked vehicle suspension system is built in accordance with the visco-elastic suspension system of structural characteristics and the feature of components. The characteristics of stiffness-damping of suspension dampers is studied by using finite element. And the loading of suspension is analyzed by applying the loading of tracked pin. Lastly, for the example of a 246 kW tracked tractor, the dynamic responding of whole machine is researched in representative working condition. The results show that the model can better reflect the characteristics of vibration damping reduction about the visco-elastic suspension system. (4 pages)Research on the simulation system of NC milling
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1428
Based on the features of NC milling process, the 3D geometric model of virtual machine tool and the fixture are established by the virtual reality technology and OpenGL graphics library with the method of construction of solid geometry (CSG) and boundary representation (B-Rep), and some realistic effects treatments (including material, light, texture mapping, etc.) are applied. The established virtual machine tool can be zoomed, rotated and translated in the view area. And a workpiece decomposition expression model based on the Z-MAP structure is put forward, and Boolean subtraction is performed by using this model and a tool solid model to simulate the real time process of cutting and test the simulation result. Simulation example proves that this system runs reliably and improves NC machining efficiency. (4 pages)Localization variation stream propagation modeling of multi-operation machining in IL&SM fixturing
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1503
The initiative locating and state memory fixturing (IL&SM) adopts the technique of freezing workpiece in space, to realize the encapsulation, fastening and clamping in the IL&SM box. IL&SM technique is designed to "free-up" the design space and greatly expand the possible range of the parts that can be machined. It is clear that locating error is one of the factors that significantly contribute to workpiece quality in the early stage of machining. Source errors are categorized into IL&SM box and locators geometric default are systematically investigated to reveal their effects upon the workpiece machining error. Variation propagation modeling has been proved to be an effective way for variation reduction and design synthesis in multi-operational processes. A state space modeling approach is developed for the localization variation synthesis and control. It provides the basis for variation control through tolerance design analysis, synthesis, and diagnosis in manufacturing systems. (5 pages)Pulsed electromagnetic separator of nonferrous metal scrap
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1647
Method of the nonferrous metals separation with respect of their mass density using the pulsed electromagnetic field is suggested in this paper. The nonferrous metals separator based on this method is presented. Results of test experiments on the real scrap obtained from the metal scrap utilizing plant are described. (3 pages)Study on the mechanisms and simulation of the tool wear process in machining of stainless steels with carbide tools
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1437
Stainless steel is a kind of difficult-to-cut materials because of its low heat conductance, poor machining quality, serious work hardening, built up edge and tool wear. In this paper, the mechanisms and varying law of tool wear vs. cutting parameters in turning stainless steels with carbide tools is first investigated by performing the systematical cutting experiments and examining with SEM instruments, and a mathematical model is derived which shows that the wear rate of the carbide tools is dependent on the cutting process variables at tool/chip and tool/work interface. In the prediction of these cutting process variables, FEM has advantages over experimental and analytical methods. Hence then the modelling techniques of chip formation process simulation by using the commercial FEM code ABAQUS are discussed. At last, a method to estimate the tool wear with the aid of FEM is proposed. With this method tool wear progress in turning operation is estimated. The predicted flank and crater wear are verified by experimental results. (5 pages)Study of fender NC incremental sheet metal forming
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1397
The principle of NC incremental sheet metal forming and the forming process of the fender are introduced. The effect of process parameters on forming is analysed. The improvement method of the forming quality is suggested. It is important that NC incremental sheet metal forming technology is perfected. The NC incremental sheet metal forming technology is a flexible forming technology without dedicated forming dies. The forming locus of the forming tool can be adjusted by correcting the numerical model of the product. Because the deformation of sheet metal only occurs around the tool head and the deformed region is subjected to stretch deformation, the deformed region of sheet metal thins, and surface area increases. Sheet metal forming stepwise is to lead to the whole sheet metal deformation. The forming half-apex angle thetas and feed pitch p are the main process parameters in NC incremental forming of fender. According to sine law, it will succeed in fender incremental forming in a single toolpath if the forming is carried out with an angle which is larger than the forming limit half-apex angle. In this study, we get the following result through calculation: thetas = 30°. The feed pitch p increase, the process time decrease, production rate and surface degree of roughness increase. In general, the feed pitch is 0.25 mm. (3 pages)Vibration and noise measurement synchronous and analysis on paper transmitting system for sheet-fed offset press
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1439
The method of synchronously measuring vibration and noise is brought forward on paper transmitting system to solve the problem of excessive vibration and noise on paper transmitting system for sheet-fed offset press and then to improve its precision.Paper transmmitting precision is influennced by excessive vibration of paper transmmitting system for sheet-fed offset press, leading to printing trouble of overlap error at a high speed. And noise level of gripper opening and closing teeth is one of the important performance indicators for sheet-fed offset press. Aiming at excessive vibration and noise of paper transmitting system for sheet-fed offset press, the principle and composition was presented in this paper. Moreover measurement at worksite was carried out. By experiment and analysis, it's known that noise level of gripper opening and closing teeth seriously affects sheet-fed offset press.The conclusion acs as the foundation for trouble diagnosis and renewing design of sheet-fed offset press. (5 pages)Characteristic of surface profile and roughness in micro turn-milling of aluminum alloy 2A12
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1424
Micro turn-milling is a new prospective technology for the precision machining of micro/meso scale rotationally symmetrical workpieces. Micro orthogonal turn-milling experiments were carried out on aluminum alloy 2A12 with high speed steel end mill in miniature turn-milling machine tool. The characteristic of surface profile were investigated using numerical characteristic parameters and mathematical statistics functions such as amplitude density function(ADF) and power spectral density (PSD). The relationship between surface roughness and cutting conditions such as machining strategy and cutting regime was established in orthogonal test and auto regression analysis. The results show that the characteristic of surface profile of up turn-milling is better than that of down turn-milling in general, the surface spatial frequency component within both of the machining strategy are deteriorated to some extent because of the irregular contact between end mill and workpiece caused by the elasticity deformation in micro turn-milling process. The surface roughness of micro turn-milling is close to micro turning and the influence of machining regime on the surface roughness is not very significant. From this perspective, the process parameters of micro turn-milling can be selected in a wide range. (4 pages)Initial results from processing of acoustic emission signals from small diameter drilling
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1702
Tool condition monitoring (TCM) measures the condition of a cutting tool used in machining, and provides the operator with information relating to the state of the process. A TCM system gathers data about a process using a number of different sensor types, including force, motor power, strain, vibration and acoustic emission. With pressure on the manufacturing industry to reduce material waste and increase productivity, the dependence on TCM systems is ever increasing. Unreliable TCM can allow a process to continue with a broken or worn tool which may damage the workpiece. This is problematic as workpieces can have a high embedded value, or the machine can be making scrap for significant periods which can be costly. On the other hand, time is wasted changing a tool too often or resetting after false alarms which is also costly. Therefore increasing the reliability of TCM systems is of critical importance to a manufacturing system. A further challenge to TCM is presented in micro machining processes, in particular with small diameter drilling. In small diameter drilling it can be very difficult to detect variations in the measurable phenomena due to the low levels recorded by sensors. One sensor that has been shown to detect valuable information during micro machining and micro drilling is an Acoustic Emission (AE) sensor. This paper outlines the an approach to processing an AE signal from micro drilling in order to provide information on the process parameters. The challenges and limitations of the analysis are discussed. (8 pages)Dynamics analysis of cutting mechanism of underwater guillotine pipe saw
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1427
In order to cut off damaged offshore pipeline, an underwater guillotine pipe saw, which was composed of sine cutting mechanism, eccentric cam mechanism and spiral feed mechanism, was designed. According to its technique process of cutting pipe, dynamic model of the guillotine pipe saw were proposed, and its simulation analyses were finished. Analytical results showed that when there were optimized parameters: cutting velocity v=480 mm/s, feed velocity v<sub xmlns="http://pub2web.metastore.ingenta.com/ns/">f</sub>=15 mm/min, height of lifting the blade in return range e=10 mm, the driving power of the guillotine pipe saw is enhanced by 2.52% due to hydrodynamic influence. Sea current has less influence on cutting work, whose reason was analyzed. Underwater experiments of the guillotine pipe saw were carried out in a port. The experimental results indicate that energy loss along hydraulic pressure pipes within 60 meters underwater was 21.7%, much more than hydrodynamic energy loss (3.3%), and error is 8.3% between test data and theory data. So the dynamic model is applicable for offshore pipeline service if the driving power of the guillotine pipe saw working in epicontinental sea is enhanced by 25% compared with working on land. What's more, the proposed dynamic model can also be used for deepwater working with underwater hydraulic power supply. (5 pages)Effect of part-cutter deflection on flexible milling force in high speed peripheral milling process
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1413
To improve the problem of dimensional accuracy of the profile for very flexible components during high speed milling process L a new method, to determine the relationship between deflection of low-rigidity process system and milling force, is approached. Based on the application of Bending-torsional coupled theory, a theoretical model to analyze the deflection of thin-walled part is determined, which can more accurately model the specific geometry and structural behaviour of the part-cutter. Taking into account the deflections the immersion angle and chip thickness have been introduced. The milling force distribution is solved iteratively by the modified Newton-Raphson method in this study. From the simulation and experimental results, it is concluded that the milling forces depend on the deflection of thin-walled part. Finally, the flexible force model has been experimentally validated and the results have shown good convergence between predicted and measured force values. (5 pages)Distribution characteristics of point discharge effect in the process of electroplating CBN gear-honing-tool
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1499
The electroplating cubic boron nitride (CBN) external gearhoning-tool is the main finishing machining tool of six to seven grade hardened gears with medium module. In the process of electroplating CBN for this gear-honing-tool, generating point discharge effect due to its metal matrix is resulted in decreasing quality of electroplated coating. That is the main factor of affecting precision and life of gear-honing-tool. In this work, positions of generating point discharge effect and affecting degree of quality of electroplated coating were analyzed on the matrix surface of gear-honing-tool. And it is the advancement method that was developed a pair of aided gears which control or eliminate tooth form error generated by point discharge effect. It was shown in experimental tests that the current density of addendum and tooth surface of CBN gear-honing-tool trended to equality by using aided gear, and the positions of point discharge effect were effectively controlled. So quality and thickness of metal electroplated coating on the addendum and tooth surface trended to uniformity. The tooth form precision of CBN gearhoning-tool was obviously improved. It is beneficial to prolonging the life of gear-honing-tool. (5 pages)Research on dynamic characteristics of printing press' paper transferring system based on experimental modal analysis
http://dl-live.theiet.org/content/conferences/10.1049/cp.2009.1487
The printing speed and print quality are depending on the dynamic characteristics of paper transferring system for a sheet-fed press. Because of the complexity of a sheet-fed press and printing technique, it is difficulty to get the real dynamic response by FEM separately, thus the boundary condition is not ease to determine while modeling. Taking the experimental platform of printing press' paper transferring system as the studying object, the experimental modal analysis was carried out with hammer pulse excitation method. The modal parameters including modal frequency, modal damping and modal shape were obtained by the result of the experimental modal analysis. The conclusion shows that the vibration characteristics of the exciting source (i.e. cam driving mechanism and gear transmission mechanism) and the compelled vibration components(i.e. the wallboard and transverse beam) need to be improved. The result of the experiment establishes a foundation of the dynamic characteristics modification for high speed paper transferring system. (6 pages)