Construction heuristics for generating tool paths for laser cutters

This paper deals with generating paths for cutting irregular parts nested on thin or thick metal sheets. The objective is to minimise the total time required to cut all parts from the metal sheet explicitly taking the cost of piercing and pre-cutting into account. The problem is modelled as a generalised travelling salesperson problem with special precedence constraints. A set of construction heuristics is presented that incorporates the constraints originating from inner–outer contours, common cuts, piercing points and pre-cuts. Computational tests on a set of real-life cutting problems show that our solution approach is able to generate tool paths that for thick plates spend on average 33.4% less time than those generated by a commercial package for air movements, pre-cuts and sharp angle macros with cutting and piercing times being equal.     

Model of megalopolises in the tool path optimisation for CNC plate cutting machines

We consider the issues of tool path optimisation under constraints and formulate a mathematical problem of visiting megalopolises. The megalopolises model is the result of the discretisation of the tool path problem for CNC plate cutting machines. The order of visits is subject to precedence constraints. In addition, the cost functions depend on the set of pending tasks. The quality criterion is a variety of the additive criterion. The problem is established within the dynamic programming framework, however, a heuristic is proposed and implemented to solve practical problems of large dimensionality.     

Manipulator motion planning for high-speed robotic laser cutting

Recent advances in laser technology, especially the increase of the cutting speed, has motivated the amendment of the existing robot path methods, which do not allow the complete utilisation of the actuator capabilities and neglect certain particularities in the mechanical design of the wrist of the manipulator arm. This research addresses the optimisation of the six-axis robot motion for continuous contour tracking while considering the redundancy caused by the tool axial symmetry. The particular contribution of the paper is in the area of multi-objective path planning using the graph-based search space representation. In contrast to previous work, the developed optimisation technique is based on dynamic programming and explicitly incorporates verification of the velocity/acceleration constraints. This allows the designer to define interactively their importance with respect to the path-smoothness objectives. In addition, this optimisation technique takes into account the capacity of certain manipulator wrist axes for unlimited rotation in order to produce more economical motion. The efficiency of the developed algorithms has been carefully investigated via computer simulation. The presented results are implemented in a commercial software package and verified for real-life applications in the automotive industry.     

Non-productive tool path optimisation for four-axis milling using the simulated annealing algorithm

The paper concerns the development of generic computer aided optimisation techniques for the minimisation of residence time of a multi-component pallet in a horizontal machining centre. A general methodology has been established to take a part program for a multi-faced pallet, that involves many components, typically 20–30, and tool changes, segment it to extract the position and machining conditions embedded in it, automatically re-sequence the machining operations to find the optimum total tool path, and regenerate a new part program with the optimised machining sequence. A range of case studies has been used to: validate the software, and to demonstrate its ability to minimise the total pallet residence time. The techniques developed can be used for semi-automatic part programming of the entire pallet with multi-components, and with an auto-selection multi-tool facility. The software is capable of achieving a large reduction in part programming time, as well as reducing the non-machining time. It is shown that the use of the optimisation package with a range of part programs reduces the total pallet residence time by a factor between 9.5 and 36%, and consequently has the potential to achieve considerable economic gains.     

Measurement of cutting tool vibrations during turning

Results are provided for an experimental study of cutting tool vibrations during turning and their effect on the surface roughness of an article being machined. __________ Translated from Izmeritel’naya Tekhnika, No. 7, pp. 22–24, July, 2006.     

Multiple-choice knapsack-based heuristic algorithm for the two-stage two-dimensional cutting stock problem in the paper industry

This study examines a two-stage two-dimensional cutting stock problem encountered by a paper mill company. The problem includes various machine-related and operational constraints based on real-world situations. Paper products are manufactured using two major cutting processes. Each cutting machine has a specific minimum and maximum width for input and output rolls and is limited by the maximum number of rolls it can cut at the same time. A mathematical model is presented to formally address the problem and an efficient multiple-choice knapsack-based heuristic algorithm is proposed to solve the problem. To demonstrate the efficiency of the proposed heuristic algorithm, computational experiments are conducted on test data-set generated from real-world data provided by a large paper mill company in the Republic of Korea.     

Tool path modification for optimized pocket milling

Many operations in CNC milling tasks are performed using pocket milling which has two main types of tool path trajectories, contour parallel path and direction parallel path. Hence there have been a lot of works on geometrically efficient algorithms to generate tool paths. Although the conventional tool path obtained from geometric information has been successful to make a desirable shape, it seldom considers physical process concerns like cutting forces and chatters. In order to cope with these problems, an optimized tool path, which maintains as constant MRR as possible in order to achieve constant cutting forces and to avoid chatter vibrations at all time, is introduced and the result is verified. Additional tool path segments are appended to the basic tool path obtained by geometric shape by using a pixel-based simulation technique. The algorithm has been implemented for two-dimensional contiguous end milling operations, and cutting tests are conducted by measuring spindle current, which reflects machining situations, to verify the significance of the proposed method.     

假肢接受腔阳模数控加工刀具的运动轨迹规划

应用表面建模方法，建立了假肢接受腔的三维数学模型。针对假肢接受腔的独特外形特征，研制了加工假肢接受腔阳模的三轴联动数控机床，该机床控制系统采用开环系统，可以运行CAD／CAM软件。对加工假肢接受腔阳模的刀具进行了运动轨迹规划，推导出了切削点的计算公式。根据三维刀具半径补偿原理，确定了刀具的刀位点运动轨迹。经过临床实例加工表明：该数控机床和刀具运动轨迹规划算法完全满足实际应用要求。     

Integrated method for tool path generation in five-axis sculptured surface machining

Five-axis machining allows continuous adjustment of cutter orientation along a tool pass. Unfortunately, the flexibility has not been fully exploited due to the separate consideration of tool path generation and cutter orientation in current machining methods. This paper presents an integrated method (IM) for tool path generation, which is tightly integrated with the orientation strategy, to minimise tool path length under the constraint of smooth cutter orientation. Distinctively, cutter orientation along a tool pass is optimised by balancing considerations of maximum material removal and smoothness of cutter movement. Further, the intervals between successive tool passes are maximised according to the optimised orientation. In the paper, the IM is combined with the quadric method, a recently developed cutter orientation strategy, for iso-parametric machining with a flat-end cutter. However, the method could be applied to other orientation strategies with different machining mechanisms and cutter types. Simulated examples illustrate that the IM is more efficient in machining than established methods.     

石墨烯纳米片增韧Al2O3基纳米复合陶瓷刀具材料

以石墨烯纳米片作为增强相,采用热压烧结工艺制备石墨烯纳米片增韧Al_2O_3基纳米复合陶瓷刀具材料。进行石墨烯纳米片分散实验,研究石墨烯纳米片添加量对刀具材料断裂韧度、抗弯强度和硬度的影响,观察其微观结构和形貌。结果表明:聚乙烯吡咯烷酮(PVP)为石墨烯纳米片的优选分散剂,当PVP添加量为石墨烯纳米片质量的60%时,分散效果最佳;当石墨烯纳米片添加量为0.75%(体积分数)时,刀具材料的断裂韧度和抗弯强度分别达到7.1MPa·m^1/2和663MPa,与未添加石墨烯纳米片的组分相比分别提高了31%和15%;石墨烯纳米片呈卷曲状结构弥散分布于基体材料中,其增韧机理为石墨烯纳米片拉断、拔出和裂纹偏转。与未添加石墨烯的刀具相比,添加石墨烯纳米片的刀具的主切削力、切削温度和前刀面摩擦因数明显降低,表现出良好的减摩、耐磨性。     

Comparative study of the effect of surface texturing on cutting tool in dry cutting

Recent researches in the field of dry machining have indicated that surface texture has the potential to influence tribological conditions. Researchers have studied the application of controlled surface microtextures on cutting tool surfaces to improve machining performance by changing the tribological conditions at the interfaces of tool–chip and tool–work piece. An experiment to study the performance of the microtextured high-speed steel cutting implement within the machining of steel and aluminum samples was performed. Surface textures were introduced using Rockwell hardness tester, Vickers hardness tester, and by scratching with diamond dresser on the face of single point cutting tool. Machining in dry conditions was applied on mild steel (EN3B) and aluminum (AA 6351) samples using lathe machine with microtextured and traditional cutting tool for the constant range of feed, depth of cut, and for varying range of cutting speeds. Measurement of cutting force, cutting temperature, and surface roughness of the work surfaces after machining were made. The results showed reduction in cutting forces and cutting temperature with textured tools in comparison with those of the untextured tool. Chips collected from different samples were studied under a microscope and the results showed that textures created on the tool surface by various methods exhibited variations in chip formation. Cutting tools without texture and with texture were comparatively studied and the outcomes of the experimental study are presented in this paper.     

皮秒激光切割AFRP复合材料实验研究

采用紫外皮秒激光(λ=355 nm)、绿光皮秒激光(λ=532 nm)和红外皮秒激光(λ=1064 nm)的三波长皮秒脉冲固体激光器,对1 mm厚芳纶纤维增强树脂基复合材料(Aramid fiber reinforced polymer,AFRP)进行单次扫描切割实验,用光学显微镜(OM)和SEM测量了上切缝宽度、切缝...     

Optimal air-move path generation based on MMAS algorithm

Air-move paths are executed by machine tools to cut 2D patterns that must retract (or turn off) when travelling from one pattern to the next. These retractions are nonproductive and hence their travelling distances should be minimised. For instance, reducing air-move time can increase the efficiency of cloth cutting in the garment industry. In this paper, a novel algorithm is proposed to solve this problem. In several past works, this problem is formulated as an instance of the generalised travelling salesman problem. We divide this problem into two independent sub-optimal problems (pattern cutting order and entry/exit cutting point) and iteratively solve them using a max–min ant system. This strategy can greatly narrow down the search space. We also perturb the pattern cutting order to avoid dowelling at a local minimum. Experiments show that the proposed algorithm is able to obtain near-optimal solutions, with the results beating the three state-of-the-art algorithms that were used as the benchmarks.     

硬质合金车刀改进前后切削能对比研究

在金属切削过程中,能量的产生与耗散时刻存在,这会直接影响加工材料的形变与加工质量。以硬质合金车刀为研究对象,借助结合理论计算、切削实验与仿真分析的研究手段,对改进的硬质合金微槽车刀和原车刀在切削高强合金钢过程中切削能的产生、传递与耗散展开研究,从能量角度揭示硬质合金微槽车刀的降温机理。研究发现,硬质合金微槽车刀较原车刀降低了切削过程的能耗,其单位总输入能、单位摩擦能、单位剪切能的降幅分别为5.1%,10.4%和3.4%;从能量耗散角度分析发现,硬质合金微槽车刀切削区平均温度低于原车刀,且理论计算和实验分析结果与仿真结果一致。研究结果为硬质合金微槽车刀的深入研究提供了理论支持,为其它类似金属加工过程中切削能量的对比研究提供了有效的参考。     

Model for thermodynamic point identification in laser cutting

In recent years, laser cutting has been introduced and developed to such an extent that it is now thought to be one of the leading and indispensable manufacturing tools. At the present time, dross‐free and accurately‐cut parts are basically regarded as the major targets to aim for, because the costs and efforts associated with dross removal by postprocessing cut parts are considerable. Therefore, control of dross formation during laser cutting is an important factor in maintaining edge quality. The initial aim of this paper is to describe the importance of physico‐mechanical material properties that need to be taken into account in modeling of laser material processing in order to control melting of the material.     

A thermal stress and failure model for laser cutting and forming operations

A transient, full three-dimensional mathematical model that describes the ablation phenomena, the thermal stress evolution, and the failure process that occur during laser cutting or forming operations on ceramic plates is developed. The model development is based on the finite element simulation of thermal field and stress development during laser cutting or forming operations. To treat the ablation phenomena during laser cutting, a fixed-grid algorithm is applied to handle complex ablation geometries with discontinuities. This algorithm is essential for applications to multiple-laser cutting operations. The thermal and stress evolution model is further integrated with a probabilistic fracture model to assess the failure probability during both laser cutting and forming processes. Numerical results show that the groove shapes as well as the temperature and stress distributions are similar in front of the cutting laser for both single and dual lasers but differ in the region when the lead laser becomes effective in dual-beam machining.     

Development of residual cutting tool life prediction algorithm by processing on CNC machine tool

The paper is dedicated to the decision of a problem of cutting tool diagnostics and working out of a remaining cutting tool life prediction algorithm. The example for practical realization of such algorithm on the CNC machine tool by machining under specified conditions is given. The question of working error compensation by means of corrective adjustment is considered.     

Cutting path optimization in CNC cutting processes using a two-step genetic algorithm

This paper deals with the problem of generating 2D cutting paths for a stock plate nested with a set of regular and/or irregular parts. The objective of the problem is to minimize the total non-productive traveling distance of a cutter starting from a known depot, then cutting all the given parts, and returning back to the depot. A cutting path consists of the depot and piercing points, each of which is to be specified for cutting a part. The cutting path optimization problem is shown to be formulated as a generalized version of the standard traveling salesman problem. To solve the problem, a two-step genetic algorithm combining global search for piercing point optimization and local search for part sequencing is proposed. Traditional genetic operators developed for continuous optimization problems are modified to effectively deal with the continuous nature of piercing-point positions. A series of computational results are provided to illustrate the validity of the proposed algorithm.     

Simulation of random tool lives in metal cutting on a flexible machine

Much research into multi-level lot-sizing problems has concentrated on fixed horizon problems ignoring more realistic conditions such as appending new demand(s) in the planning periods. The aim of this paper is to illustrate that a heuristic, which was developed earlier by the authors, is applicable to the multilevel lot-sizing problem with a bottleneck under a rolling schedule environment. The results illustrate that the Silver-Meal (SM) approach performed better than the Economic Order Quantity (EOQ) approach in terms of cost measures, when incorporated within the heuristic procedure. The results also show that, although the total cost of the problem is increased in a rolling schedule environment, the heuristic continues to perform favourably in producing low cost solutions.