Dimensional Analysis of Workpieces Machined Using Prototype Machine Tool Integrating 3D Scanning, Milling and Shaped Grinding
Abstract
:1. Introduction
- DMG MORI CTX gamma 2000 TC;
- DMG MORI LASERTEC 65 3D;
- Doosan PUMA SMX3100L.
- X11 Powered Electrospindle;
- Broaching Toolholder;
- Driven Gear Hobber;
- Laser cutting device for turret lathes.
- laser head;
- PLC controller for numerical control;
- a device for automatically picking up and depositing the laser head into a dedicated warehouse mounted near the CNC lathe spindle.
2. Materials and Methods
2.1. Dedicated Test Piece
2.2. Prototype Machine Tool Integrating 3D Scanning, Milling, and Shaped Grinding
- generation of G-codes for the CNC machine to perform the spatial scanning process;
- editing of 3D model geometry;
- saving of the scanned geometry of the model in the formats *.stl, *.dxf and *.bmp.
2.3. Machining Center for Making Elements and Verification of Dimensional and Shape Accuracy
2.4. Workpiece Material
2.5. Machining Parameters and CAM Machining Program
- face planning (face);
- 2D roughing of the selected flat surface (adaptive);
- 2D finishing milling of the selected contour (contour);
- opening milling (bore);
- finishing 3D profile milling (parallel).
- HAAS pre-NGC—for the HAAS VF-2 milling center;
- Mach3Mill—for a prototype machine tool integrating 3D scanning, milling, and smoothing of contoured surfaces.
2.6. Measurement Systems
3. Results and Discussion
4. Conclusions
- The use of Mach 3 program as a control system and CNC LPT Mach3 controller made it possible to integrate all elements of the machine tool and allowed to carry out 3D scanning, milling, and smoothing of shaped surfaces on one machine tool.
- The shape of the developed test piece made it possible to assess both the accuracy of dimensions and shape of flat, cylindrical and shaped surfaces as well as surface texture using a multicriteria approach.
- Results of the comparative analysis of variance by the ANOVA method of the influence of machining method on the geometric accuracy of the test pieces showed that, in four cases out of six, evaluated features (flatness deviation: p = 0.076764, vertical parallelism deviation: p = 0.737167, opening dimensions deviation: p = 0.510757, and opening cylindricality deviation: p = 0.197715) showed no statistically significant differences.
- The same analysis showed a statistically significant influence of the applied machine tool on a dimensional deviation between flat surfaces (p = 0.010467) and horizontal parallelism deviation (p = 0.0).
- ANOVA also indicated a statistically significant influence of the applied machine tool on the quality of the machined surface defined by four surface texture parameters: Ra (p = 0.831797), Rt (p = 0.759636), Rq (p = 0.867222), and Rz (p = 0.651896).
- Analyses of the significance of the influence of the applied machine tool on the value of particular parameters allowed us to determine the areas of compatibility of results obtained using both compared machines.
- The demonstrated nonconformities result from insufficient rigidity of the prototype machine tool’s gantry construction as well as from the type of bearings used in the kinematic system (in at least one of the working axes of the machine).
- To increase the dimensional and shape accuracy of elements made with the use of the prototype machine tool, it is necessary to stiffen its structure and change the type of bearings in the kinematic system of the machine tool.
- The carried out research allowed us to define the strengths and weaknesses of the prototype machine tool integrating 3D scanning, milling, and shaped grinding, which will lead to the elimination of the detected imperfections and further analysis of technological strategies and possible benefits of integrating machining operations.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
Nomenclature
ACT | Abrasive Computer Tomography |
ANOVA | Analysis of Variance |
CAD | Computer-Aided Design |
CAM | Computer-Aided Manufacturing |
CNC | Computerized Numerical Control |
LDS | Laser Displacement Sensor |
NC | Numerical Control |
SLS | Slit Laser Scanner |
n | Number of repetitions |
p | Probability |
Ra | Arithmetical mean deviation of the roughness profile, μm |
Rq | Root-mean-square deviation of the roughness profile, μm |
Rt | Total height of the profile within a sampling length, μm |
Rz | Maximum height of the profile within a sampling length, μm |
E | Modulus of elasticity, MPa |
G | Shear modulus, MPa |
α | Confidence level |
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Integrated Methods | Area of Application | Author(s) | Reference |
---|---|---|---|
3D scanning (triangulation) + CNC machining (milling) | Free-form surfaces and quadric surfaces | Bradley et al. (1992) | [4] |
3D scanning (LDS) + NC machining | Aerospace industry, large thin-walled parts | Liu et al. (2015) | [5] |
3D scanning + CNC machining (milling) | Small-engineering parts | Wu et al. (2014) | [6] |
3D scanning (SLS) + CNC machining (milling) | Galantucci et al. (2015) | [7] | |
3D scanning (ACT) + CNC machining (milling) | Orthodontics, orthodontic denture | Chang et al. (2006) | [8] |
3D scanning (triangulation) + CNC machining (milling) | Dentistry, dental restorations | Milde and Morovič (2016) | [9] |
Hardness | 110 HB |
Solidification temperature | 510 °C |
Pour point | 645 °C |
Density | 2.79 g/cm3 |
Poisson number | 0.33 |
Thermal expansion coefficient | 22.9 μm/mK |
Specific heat | 873 J/kgK |
Specific resistance | 51 nWm |
Conductivity | 34% IACS (International Annealed Copper Standard) |
Thermal conductivity | 134 W/mK |
Shear modulus G | 27,200 MPa |
Modulus of elasticity E | 72,500 MPa |
Technological Operations | Tool | Parameters | |
---|---|---|---|
Feed Speed, mm/min | Spindle Speed, rpm | ||
Face planning | MM06.55.3.AL | 600 | 8000 |
2D roughing of the selected flat surface | MM06.55.3.AL | 600 | 8000 |
2D finishing milling of the selected contour | MM06.55.3.AL | 600 | 8000 |
Opening milling | MM06.55.3.AL | 600 | 8000 |
Finishing 3D profile milling | MM06.55.2.R3.Al | 240 | 6000 |
Grinding (smoothing) | Compressed nonwoven disc, 3M XL-DR, diameter 75 mm, granulation 2S FIN | 50 | 8000 |
Analyzed Feature | Sum of Squares of Effects SS | Degrees of Freedom | Number of Degrees of Effects MS | F Test Value | Probability Level p | Is the Machining Method Significant? | |
---|---|---|---|---|---|---|---|
Flatness deviation | Free term | 0.045138 | 1 | 0.045138 | 348.1856 | 0.000000 | Yes |
Flatness | 0.003126 | 10 | 0.000313 | 2.4115 | 0.021973 | Yes | |
Method | 0.002698 | 1 | 0.002698 | 20.8139 | 0.000040 | Yes | |
Flatness × Method | 0.002418 | 10 | 0.000242 | 1.8653 | 0.076764 | No | |
Error | 0.005704 | 44 | 0.000130 | – | – | – | |
Dimensional deviation between flat surfaces | Free term | 0.002203 | 1 | 0.002203 | 4.26330 | 0.042760 | Yes |
Dimensions | 0.059508 | 16 | 0.003719 | 7.19858 | 0.000000 | Yes | |
Method | 0.016063 | 1 | 0.016063 | 31.08918 | 0.000000 | Yes | |
Dimensions × Method | 0.073535 | 16 | 0.004596 | 8.89535 | 0.000000 | Yes | |
Error | 0.035133 | 68 | 0.000517 | – | – | – | |
Horizontal parallelism deviation | Free term | 0.091963 | 1 | 0.091963 | 580.0884 | 0.000000 | Yes |
Horizontal parallelism | 0.003789 | 9 | 0.000421 | 2.6559 | 0.016255 | Yes | |
Method | 0.026924 | 1 | 0.026924 | 169.8319 | 0.000000 | Yes | |
Horizontal parallelism × Method | 0.004089 | 9 | 0.000454 | 2.8657 | 0.010467 | Yes | |
Error | 0.006341 | 40 | 0.000159 | – | – | – | |
Vertical parallelism deviation | Free term | 0.837260 | 1 | 0.837260 | 157.6767 | 0.000000 | Yes |
Vertical parallelism | 0.156567 | 6 | 0.026095 | 4.9142 | 0.001515 | Yes | |
Method | 0.003155 | 1 | 0.003155 | 0.5941 | 0.447293 | No | |
Vertical parallelism × Method | 0.018725 | 6 | 0.003121 | 0.5877 | 0.737167 | No | |
Error | 0.148679 | 28 | 0.005310 | – | – | – | |
Opening dimensions deviation | Free term | 0.010561 | 1 | 0.010561 | 104.2237 | 0.000007 | Yes |
Opening dimensions | 0.000003 | 1 | 0.000003 | 0.0296 | 0.867662 | No | |
Method | 0.000147 | 1 | 0.000147 | 1.4507 | 0.262843 | No | |
Opening dimensions × Method | 0.000048 | 1 | 0.000048 | 0.4737 | 0.510757 | No | |
Error | 0.000811 | 8 | 0.000101 | – | – | – | |
Opening cylindricality deviation | Free term | 0.000784 | 1 | 0.000784 | 19.32033 | 0.002301 | Yes |
Opening cylindricality | 0.000044 | 1 | 0.000044 | 1.08624 | 0.327775 | No | |
Method | 0.000140 | 1 | 0.000140 | 3.45175 | 0.100255 | No | |
Opening cylindrica-lity × Method | 0.000080 | 1 | 0.000080 | 1.97331 | 0.197715 | No | |
Error | 0.000325 | 8 | 0.000041 | – | – | – |
Analyzed Feature | Sum of Squares of Effects SS | Degrees of Freedom | Number of Degrees of Effects MS | F Test Value | Probability Level p | Is the Machining Method Significant? | |
---|---|---|---|---|---|---|---|
Arithmetical mean deviation of the roughness profile Ra | Free term | 0.352800 | 1 | 0.352800 | 242.3817 | 0.000000 | Yes |
Ra | 0.000233 | 2 | 0.000117 | 0.0802 | 0.923465 | Yes | |
Method | 0.128356 | 1 | 0.128356 | 88.1832 | 0.000001 | Yes | |
Ra × Method | 0.000544 | 2 | 0.000272 | 0.1870 | 0.831797 | Yes | |
Error | 0.017467 | 12 | 0.001456 | – | – | – | |
Total height of the profile within a sampling length Rt | Free term | 20.90889 | 1 | 20.90889 | 181.7901 | 0.000000 | Yes |
Rt | 0.02431 | 2 | 0.01216 | 0.1057 | 0.900536 | Yes | |
Method | 5.89389 | 1 | 5.89389 | 51.2438 | 0.000012 | Yes | |
Rt × Method | 0.06471 | 2 | 0.03236 | 0.2813 | 0.759636 | Yes | |
Error | 1.38020 | 12 | 0.11502 | – | – | – | |
Root mean square deviation of the roughness profile Rq | Free term | 0.590422 | 1 | 0.590422 | 243.1945 | 0.000000 | Yes |
Rq | 0.000544 | 2 | 0.000272 | 0.1121 | 0.894855 | Yes | |
Method | 0.204800 | 1 | 0.204800 | 84.3570 | 0.000001 | Yes | |
Rq × Method | 0.000700 | 2 | 0.000350 | 0.1442 | 0.867222 | Yes | |
Error | 0.029133 | 12 | 0.002428 | – | – | – | |
Maximum height of the profile within a sampling length Rz | Free term | 11.09205 | 1 | 11.09205 | 205.4929 | 0.000000 | Yes |
Rz | 0.01743 | 2 | 0.00872 | 0.1615 | 0.852697 | Yes | |
Method | 3.33681 | 1 | 3.33681 | 61.8181 | 0.000004 | Yes | |
Rz × Method | 0.04788 | 2 | 0.02394 | 0.4435 | 0.651896 | Yes | |
Error | 0.64773 | 12 | 0.05398 | – | – | – |
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Jaskólski, P.; Nadolny, K.; Kukiełka, K.; Kapłonek, W.; Pimenov, D.Y.; Sharma, S. Dimensional Analysis of Workpieces Machined Using Prototype Machine Tool Integrating 3D Scanning, Milling and Shaped Grinding. Materials 2020, 13, 5663. https://doi.org/10.3390/ma13245663
Jaskólski P, Nadolny K, Kukiełka K, Kapłonek W, Pimenov DY, Sharma S. Dimensional Analysis of Workpieces Machined Using Prototype Machine Tool Integrating 3D Scanning, Milling and Shaped Grinding. Materials. 2020; 13(24):5663. https://doi.org/10.3390/ma13245663
Chicago/Turabian StyleJaskólski, Piotr, Krzysztof Nadolny, Krzysztof Kukiełka, Wojciech Kapłonek, Danil Yurievich Pimenov, and Shubham Sharma. 2020. "Dimensional Analysis of Workpieces Machined Using Prototype Machine Tool Integrating 3D Scanning, Milling and Shaped Grinding" Materials 13, no. 24: 5663. https://doi.org/10.3390/ma13245663