Key Engineering Materials Vols. 407-408

Abstract: A strategy of toolpath generation based on Tool-Zmap geometric model has been proposed to achieve efficient finish machining of mold cavity. Considering cutting tool wear, the finish machining of mold cavity was performed using variable cutting tools of different diameter. Each cutting tool only cuts the corresponding area to avoid identifying machining characteristic and poor rigidity of cutting tool during high speed machining. Finally, the validity of presented strategy was experimentally affirmed by a machining example.

Abstract: Conical screw rotor is the key part of conical double-screw extruder, with complex geometrical features, such as variable outside and inside diameter, unequal groove depth, varied head and lead. The manufacturing process is complicated and difficult. The precision and efficiency of conventional machining method is lower, the mating character of machined screw rotor is bad and the exchangeability is hard. On the basis of studying the geometric character and contacting process of double conical screw, this paper presents a new NC manufacturing method to envelope milling screw rotor with several axes moving combined. The automatic programming system for screw rotor NC machining is developed. This research increases the machining level of conical double screw. It has conspicuous engineering meaning.

Abstract: Software applications for manufacturing systems developed using software from different vendors typically cannot work together. Develop¬ment of custom integrations of manufacturing software incurs costs and delays that hurt industry productivity and competitiveness. Software applications need to be tested in live operational systems. It is impractical to use real industrial systems to support dynamic interoperability test¬ing and research due to: 1) access issues - manu¬facturing facilities are not open to outsiders, as proprietary data and processes may be compro¬mised; 2) technical issues - operational systems are not instrumented to support testing; and 3) cost issues - productivity suffers when actual production systems are taken offline to allow testing. Publicly available simulations do not exist to demonstrate simulation integration issues, validate potential standards solu¬tions, or dynamically test the interoperability of simulation systems and other software applica¬tions. A new, dynamic, simulation-based interoperability testing facility for manufacturing software applications is being developed at the National Institute of Standards and Technology (NIST).

Abstract: Aimed at the complexities about information integration of manufacturing process, the architecture ,method and technique that are used to realize information integration of manufacturing process for aviation manufacturing enterprise are studied，and the example of applying web services to integrate ERP and MES in an aviation manufacturing enterprise is introduced，the result of the application shows that manufacturing process can be integrated effectively using web services. Finally, the future work about the research is introduced.

Abstract: A flank milling tool positioning method using a barrel cutter is proposed. An offset point is used as the first anchor point. Two rotary angles of the barrel cutter are adjusted to find the optimized tool position with the largest machining strip width. The result tool position calculated using the proposed method is gouge-free because the local interference avoidance method is integrated inside the tool positioning procedure. Error distribution beneath the barrel cutter is well estimated by virtual of the instant envelope curve of the cutter. The envelope curve is discretized into points. The distances between these points and the model surface are the machining errors beneath the cutter. The employment of the envelope curve also largely reduces the computational load of the algorithm. Finally, numerical implementation and simulation are performed to validate the feasibility of the method.

Abstract: One of the major barriers to the integration of CAD, CAPP and CAM is insufficiency and incompatibility of product model data among various application systems. This paper presented an effective approach to achieve integrated process planning with CAD and CAM under a product data management environment based on 3D product models. The system architecture and the processes of an integrated process planning system (3D-IPP) were constructed using feature information and specific CAD/CAPP/CAM integration technologies based on feature. A feature-based product information model is designed as the information source for the 3D-IPP. A feature-based integrated process planning method was developed based on group technology, intelligent decision-making algorithms and parametric operation templates in numerically controlled (NC) programming. The procedures of intelligent process route planning and parametric NC operation planning were addressed. The 3D-IPP system and its implementation provide an effective solution to strive for complete information sharing among application systems of CAD, CAPP and CAM.

Abstract: This paper describes an analytical formulation and a numerical solution of the elastic dynamic problems of non-homogeneous poroelastic shells of revolution saturated in viscous fluid. The porosity and porous diameter of the material are assumed to be continuously varied along the shell thickness. The equations of motion and the relations between strains and displacements are derived by extending the Sanders shell theory. As the constitutive relations, the consolidation theory of Biot for models of fluid-solid mixtures is employed. The flow of viscous fluid through a porous elastic solid is governed by Darcy's law. In the numerical analysis of the fundamental equations an usual finite difference form is employed for the spatial derivatives and the inertia terms are treated with the backward difference formula proposed by Houbolt. As a numerical example, the simply supported cylindrical shell under a semi-sinusoidal internal load with respect to time is analyzed. Numerical computations are carried out by changing porosity and mean void radius along the shell thickness, and the variations of pore pressure, displacements and internal forces with time are analyzed.

Abstract: Cutting fluid occupies an important position in the metal processing. The performance and pollution problem brought to the environment of cutting fluid are paid attention to day by day. Proceed from the perspective of green design, using castor oil which has a good biodegradability, triethanolamine, boric acid and the sodium polyacrylate whose molecular weight is less than 2×104 as the main raw materials, a boron-containing water-based cutting fluid had been obtained. The performance of B-containing water-based cutting fluid are measured according to GB/T6144-1985 regulation which is the technical requirements of synthetic cutting fluid. And the biodegradability of mineral oil, castor oil, modified castor oil and B-containing water-based cutting fluid are measured by improved Storstroem Test (OECD301B). The test results show that the B-containing water-based cutting fluid has a good performance of physical and chemical. And the biodegradation rate of the cutting fluid is 87%, which indicates the cutting fluid has a good biodegradability.

Abstract: To reduce the management cost and environmental load of water-soluble coolant, authors have been studying on a metabolic system for water-soluble coolant. More than 90% of waste water-soluble coolant is composed of water phase. If the oily additives and contaminants can be isolated from the waste coolant, the amount of waste coolant decreases remarkably because the recycled water can be reutilized as a diluent of renewal coolant. Authors has been developed some types of water recovery methods for the metabolic system. To complete the metabolic system for water-soluble coolant, the coolant diluted with recovered water should have the same machining performance and long-term stability as those of coolant diluted with tap water. In this report, we examined the machining performance and ability change of water-soluble coolant diluted with recycled water under operations encountered in machine tool.

Abstract: The cutting fluid is widely used in cutting process with the cemented carbide tool. This paper studied the influence of some antirusting aggents, such as triethanolamine, tri-sodium phosphate, benzotriazole, sodium carbonate anhydrous, on the cobalt leaching of the cemented carbide tool by soaking test. The test results showed that a cobalt on cememted carbide surface and triethanolamine can produce complex compound into solution that made the cobalt leaching. The cobalt of the cemented carbide with the ion of the tri-Sodium phosphate in a water solution can form the loose deposition which leaded to the cobalt leaching.The benzotriazole and the cobalt can generate complex compound film covering on cemented carbide to effective inhibits the cobalt leaching. The inhibitive effect about the cobalt leaching of the sodium carbonate anhydrous is carried out through cathode reaction. The cobalt leaching of cemented carbide tool is effective inhibited by adding the benzotriazole and the carbonate anhydrous in the water-based cutting fluid.