ICMAS

 

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PROCEEDINGS IN MANUFACTURING SYSTEMS

ISSN 2343–7472

ISSN-L 2067–9238

 

 

 

 

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Journal

PROCEEDINGS

IN MANUFACTURING SYSTEMS

 

Volume 8, Issue 2,  2013

 

 

Contents

 

·     Uros ZUPERL,

Swarm intelligence combined with neural network objective function modelling for turning process optimization

 

· Gerhard KEHL

FE-simulation of machine tool with integrated cutting process to answer the crucial question: “will it cut or won’t it ?

 

· Christian LANDSCHÜTZER, Andreas WOLFSCHLUCKNER, Dirk JODIN,

CAE for high performance in-feed processes at sorting systems

 

· Ludmila NOVAKOVA-MARCINCINOVA, Jozef NOVAK-MARCINCIN,

Verification of mechanical properties of ABS materials used in FDM rapid prototyping technology

 

· Georgi TODOROV, Tsvetozar IVANOV, Konstantin KAMBEROV, Boyko ALADJEMOV,

Engineering design and analysis of nozzle assembly for water sports training device

 

· Oskar ZEMČÍK, Josef CHLADIL, Jan OTOUPALÍK, Josef SEDLÁK,

Changes in the surface layer of rolled bearing steel

 

· Mariana ROTARIU, Dragos AROTARITEI, Marius TURNEA, Robert FILEP,

Hypertrophic scar formation model applied to blunt--prosthesis interface: forming by accretion

 

· Aurel FRATU, Michel DAMBRINE,

An analysis of the robot collision avoidance using the programming through imitation

 

· Veronika IVANOVA, Krassimira KOLEVA, Radko MIHAILOV, Iossif BENIOZEF,

Family tools for robot-assisted surgery

 

 

pp. 69-74

 

SWARM INTELLIGENCE COMBINED WITH NEURAL NETWORK OBJECTIVE FUNCTION MODELLING FOR TURNING PROCESS OPTIMIZATION

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Uros ZUPERL

 

1) Assist. Prof., researcher, University of Maribor, Faculty of mechanical engineering, Maribor, Slovenia

 

Abstract: This paper discusses the use of non-traditional optimization technique based on combination of artificial neural network and swarm intelligence for optimization of cutting parameters in turning.

An artificial neural network model (ANN) was used to predict objective function during optimization and particle swarm optimization algorithm (PSO) was used to obtain optimum cutting speed and feed rate. This paper also presents fundamentals of ANN-PSO optimization technique. The study also incorporates the manufacturer’s value system into a combined neuro–swarm system to optimize the cutting parameters. An objective function based on manufacturer’s multi-attribute function is used. The optimization process considers the practical constraints, such as maximum machine power, force, allowable speed, feedrate and surface requirement. The objective is to find the best parameter settings to maximize the production rate and surface quality and to minimize the production costs. The results indicate that the proposed optimization system is efficient and accurate compared to other methods developed by other researchers. This paper compares the results of proposed optimization system with the GA, ACO and simulated annealing (SA). The optimization system should be used for the fast approximate determination of optimum cutting conditions on the machine, when there is not enough time for deep analysis.

 

Key words: machining, optimization, swarm intelligence, neural network.

 

 

pp. 75-78

 

FE-SIMULATION OF MACHINE TOOL WITH INTEGRATED CUTTING PROCESS TO ANSWER THE CRUCIAL QUESTION: “WILL IT CUT OR WON’T IT ?”  

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Gerhard KEHL

 

1) Prof. Dr.-Ing., University of Applied Sciences, Faculty of Engineering Management, Esslingen, Germany

 

Abstract: In recent years, the use of simulation-aided methods has become well-established in machine tool development. Structural dynamics, for instance, are evaluated and optimized on the basis of simulated compliance frequency responses. This allows to compare alternative conceptual variants, however, it does not allow authoritative statements to be made in terms of process stability of specific machining processes. To simulate the dynamic overall behavior and thus answer the above-mentioned question, it is necessary to couple machine model and process model. Precondition for this are qualified machine and process models. The machine model of a machining centre must on the one hand map the mechanical structure with the integrated drives and controls, and on the other hand describe in detail the spindle system. The process model based on analytic model conceptions should be able to map all relevant effects of machining processes like turning, milling or drilling. This article discusses the following points from a machine tool manufacturers perspective: FE modeling and simulation of the machine tool; coupling of machine model and process model by compliance frequency response; stability analysis by FE simulation with integrated cutting process model; experiences and limitations regarding the forecasting capability of this simulation; future steps for further development.

Key words: FE simulation, design, machine tool, cutting process, process stability, cutting depth, regenerative chatter.

 

 

pp. 79-86

 

CAE FOR HIGH PERFORMANCE IN-FEED PROCESSES AT SORTING SYSTEMS

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Christian LANDSCHÜTZER1,*, Andreas WOLFSCHLUCKNER2, Dirk JODIN3

 

1) Ass.Prof. Dipl.-Ing. Dr.techn., TU Graz, Institute of Logistics Engineering, Graz, Austria

2) Dipl-Ing., PhD candidate, TU Graz, Institute of Logistics Engineering, Graz, Austria

3) Univ.-Prof. Dr.-Ing. habil., head of Institute, TU Graz, Institute of Logistics Engineering, Graz, Austria

 

Abstract: This paper concludes the first steps for CAE with sorting systems from ICMaS’12. As high performance sorting processes are more and more relevant not only but very much from e-commerce business engineering is addressed to bring faster, more accurate and safer technologies therein. The authors describe the in-feed-process, identified as a crucial one for extending sorter performance. An analytical solution (2D) for the “classic” belt feeder is presented and compared with a multibody model. Valuable insights for modelling, effort and practical use are demonstrated. A MBD-simulation is presented and an overview shows where and how to adjust the design from simulation findings.

 

Key words: CAE, Multi Body Dynamics/Simulation (MBD, MBS), sortation system, tilt tray sorter, in feed process, design optimization, design of experiments.

 

 

pp. 87-92

 

VERIFICATION OF MECHANICAL PROPERTIES OF ABS MATERIALS USED IN FDM RAPID PROTOTYPING TECHNOLOGY

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Ludmila NOVAKOVA-MARCINCINOVA1,*, Jozef NOVAK-MARCINCIN2

 

1) Eng., scientific worker, Faculty of Manufacturing Technologies, Technical University of Kosice, Presov, Slovakia

2) PhD, Prof., Faculty of Manufacturing Technologies, Technical University of Kosice, Presov, Slovakia

 

Abstract: In this paper, information about common and advanced materials used for manufacturing of products by Fused Deposition Modelling (FDM) rapid prototyping technology is presented. In different rapid prototyping technologies the initial state of material can come in either solid, liquid or powder state. The current range materials include paper, nylon, wax, resins, metals and ceramics. In FDM as basic materials ABS - Acrylonitrile Butadiene Styrene, polyamide, polycarbonate, polyethylene and polypropylene are mainly used. Main part of the paper is focused on experimental testing of rapid prototyping materials realized by different research teams and presents outputs of testing of ABS material in FDM technology realized by authors.

 

Key words: fused deposition modeling, Acrylonitrile Butadiene Styrene, mechanical properties.

 

 

pp. 93-98

 

ENGINEERING DESIGN AND ANALYSIS OF NOZZLE ASSEMBLY FOR WATER SPORTS TRAINING DEVICE

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Georgi TODOROV1*, Tsvetozar IVANOV2, Konstantin KAMBEROV3, Boyko ALADJEMOV4

 

1) Prof., PhD Eng., Dean, Faculty of Industrial Technologies, Technical University, Sofia, Bulgaria

2) Eng., Research Engineer, Laboratory “CAD/CAM/CAE in Industry”, Technical University, Sofia, Bulgaria

3) PhD Eng., Research Engineer, Laboratory “CAD/CAM/CAE in Industry”, Technical University, Sofia, Bulgaria

4) Eng., Research Engineer, Laboratory “CAD/CAM/CAE in Industry”, Technical University, Sofia, Bulgaria

 

Abstract: Virtual engineering usually is applied as to reduce time/money spent for product development stage, but also is a powerful basis to explore details that might otherwise remain undetected. New products development process is demonstrated based on virtual engineering techniques application, forming new, coupled approach. Alternating between CAD enhanced design and numerical techniques (CFD analysis) are in the core of applied approach to design flowboarding training device. This approach enables to implement manufacturing constraints in each step of design development as to produce structure that not only suits technical requirements, but also is cost effective. Simulated physics is also challenging as it concerns two phases (water and air) fluids mixture. The study is focused on the major component of examined structure – nozzle assembly. It should provide sufficient fluid flow at certain pressure losses while correspond to certain requirements for produced water layer. Detailed product design is evolved through initial conception study and characterization to final design exploration, using contemporary tools, applied over common virtual prototype. Major advantages of this approach are mixing (alternating) manufacturing constraints requirements with technical requirements that results in a perspective design, decreasing required time for its development.

 

Key words: CAD, Engineering analysis, CFD, wave-forming generator, nozzle.

 

 

pp. 99-104

 

CHANGES IN THE SURFACE LAYER OF ROLLED BEARING STEEL

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Oskar ZEMČÍK 1,*, Josef CHLADIL2, Jan OTOUPALÍK3, Josef SEDLÁK4

 

1) Ing., Ph.D., lecturer, Faculty of Mechanical Engineering, Institute of Manufacturing Technology, Brno, Czech Republic

 2) doc. Ing., PhD., lecturer, Faculty of Mechanical Engineering, Institute of Manufacturing Technology, Brno, Czech Republic

3) Ing., Ph.D. student, Faculty of Mechanical Engineering, Institute of Manufacturing Technology, Brno, Czech Republic

4) Ing., Ph.D., lecturer, Faculty of Mechanical Engineering, Institute of Manufacturing Technology, Brno, Czech Republic

 

Abstract: The article deals with the changes in the surface layer of the ring of rolled bearing steels. The additional method of hydrostatic roller burnishing operation is applied on samples of material 100Cr6 (EN 10132-4) and changes in the surface layer of the workpiece are then evaluated. The simulation using finite element method was used to better understand the ongoing phenomena.

 

Key words: bearing steel, roller burnishing, finite element method, residual austenite, residual stress

 

 

pp. 105-110

 

HYPERTROPHIC SCAR FORMATION MODEL APPLIED TO BLUNT--PROSTHESIS INTERFACE: FORMING BY ACCRETION

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Mariana ROTARIU1, Dragos AROTARITEI2,*, Marius TURNEA3, Robert FILEP4

 

1) As., PhD student, University of Medicine and Pharmacy “Grigore T. Popa”, Iasi, Romania

2) Prof., PhD, University of Medicine and Pharmacy “Grigore T. Popa”, Iasi, Romania

3) As. Prof., PhD, University of Medicine and Pharmacy “Grigore T. Popa”, Iasi, Romania

4) PhD student, OrtoProfil, Targu Mures, Romania

 

Abstract: The interface blunt-prosthesis is the subject of stress and friction due to forces that act in the walking stage. The dermal wounds that can appear due to this stress and frictions can heal due to normal process of regenerative of dermal layers. In some cases, the normal process of wound healing can fail and some abnormal forms can develop: keloid and hypertrophic scars. These abnormal forms can be seen as mainly due to fibro-proliferative disorder in terms of excessive development of fibroblastic cells. In this paper we investigated the possibility to use the mathematical model for fibro-proliferative interactions to forming of scars by accretion at the interface blunt-prosthesis. The work can be used to predict the risk area of patient’s stump and subsequent the use of physio kinetotherapy program to prevent this. The investigation is a theoretically one and it must be validated by medical measurements.

 

Key words: mathematical model, fibroplasia and wound contraction, hypertrophic scar, fibro-proliferative disorders, blunt-prosthesis interface, cell accretion.

 

 

 

pp. 111-116

 

AN ANALYSIS OF THE ROBOT COLLISION AVOIDANCE USING THE PROGRAMMING THROUGH IMITATION

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Aurel FRATU1,*, Michel DAMBRINE2, 3

 

1) Prof., PhD, Dept. of Automatics, Electronics and Computers, „Transilvania” University of Braşov, Brasov, Romania

2) Prof., PhD, Univ Lille Nord de France, F-59000 Lille, France,

3) UVHC, LAMIH, F-59313 Valenciennes, France

 

Abstract: This paper presents an analysis of the collision avoidance of the cooperative robots using the programming through imitation. Each physical robot acts fully independently, communicating with corresponding virtual prototype and imitating her behavior. Each physical robot reproduces the motion of her virtual prototype. The estimation of the collision-free actions of the virtual cooperative robots and the transfer of the virtual joint trajectories to the physical robots who imitate there virtual prototypes, are the original ideas. We tested the present strategy on several simulation scenarios, involving two virtual robots and estimating collision-free actions, during of the cooperative tasks.

 

Key words: virtual robots, cooperative robots, collision avoidance, motion imitation.

 

 

pp. 117-122

 

FAMILY TOOLS FOR ROBOT-ASSISTED SURGERY

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Veronika IVANOVA1,*, Krassimira KOLEVA2, Radko MIHAILOV3, Iossif BENIOZEF4

 

1) PhD, Department of Robotized executive mechanisms and Intelligent Systems, Institute of  Systems Engineering and Robotics Bulgarian Academy of Sciences, Sofia, Bulgaria

 2) Assistant, Department of Technical Mechanics, Technical University of Varna, Varna, Bulgaria

3) Assoc. Professor, College of Technology to The Technical University o fVarna, Dobrich, Bulgaria

4) Engineer, Department of Robotized executive mechanisms and Intelligent Systems Institute of Systems Engineering and Robotics Bulgarian Academy of Sciences, Sofia, Bulgaria

 

Abstract: Medical technology trends to the design and development of novel type of executive tools and accessories, allowing improving the performance of medical staff and increasing quality of care for patients. Amongst them, laparoscopic surgery is very popular medical intervention for diagnoses and treatment some abdominal problems and diseases. However, the lack of tactile sense is the cardinal disadvantage associated with laparoscopy, because it limits the surgeon abilities.  In this context the main objective of the work is to investigation of current laparoscopic instruments and robot assisted systems, and design novel type family tools for robot-assisted surgery with better technical characteristics, and incorporation of force sensors in construction of instruments for restore sense of touch and recognizing the presence of contact at end –effectors with organs tissues and stones during surgical procedures. Thus it is improving some technical side of these laparoscopic instruments. Also this paper shows common examples for tool-object force interaction at different type end -effectors. To avoid cardinal disadvantage on existing direct sensing control methods for tissue characterization, different approaches is proposed. For this purpose an original instrument with two force sensors by Honeywell Company, position sensor and linear driving mechanism implemented there was designed and produced. This laparoscopic tool is main component in haptics control system for tissues characterization. During the designing process of family tools for robot-assisted surgery following main problems have to be overtaken: i) presence of tactile force feedback, ii) ability to force control and its regulation in requested range.  

 

Key words: robotics, mechatronics, robot-assisted surgery, laparoscopic instruments, tactile sense, haptic device

 

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