During the 17th CIRP Conference on Modeling of Machining Operations there will be six on-machine demonstrations.
Please see below for descriptions of the demonstrations at CIRP CMMO 2019
1. Online Simulation
The online simulation integrates conventional desktop simulation capability with true machine measurements in order to evaluate operations in real time. This system utilizes data from the machine controller (axes positions, spindle speed, spindle torque etc.) and applies it directly to a cutting force simulation. Comparison of the simulated and measured results provides insight into the health of the operation, as well as the accuracy of the simulation. In this demonstration, the online simulation will be applied to tailor cutting force coefficients in order to provide accurate baseline results throughout the operation.
2. Live Data Monitoring in Machining
A data capture, analysis and visualization system that can show both live and historic machining data will be presented. We will use a live machining demonstration to show how data can be viewed in real-time as the NC program runs, and then how this data can be retrospectively analysed after machining has finished.
3. Hybrid Machining
Hybrid machining combines the flexibility of the laser metal deposition process with the precision of the cutting process and allows additive manufacturing in milling quality. The process uses the metal deposition by powder nozzle, which is up to 10-times faster than the generation in powder bed solutions. These can have internal features included in them and can be made out of different materials. Parts can be coated with advanced materials for better wear resistance.
4. 6-Axis Waterjet
The AMRC has recently obtained new 6-axis Staubli TX200 robotic abrasive water jet machine from Flow Aquarese. The demo will introduce the capabilities and advantages of the abrasive water jet (AWJ) machine for cutting of difficult to machine materials like carbon fibre, titanium, nickel-based alloys or ceramics. Water jet cutting can produce complex part geometry across a large range of materials without introducing thermal distortion or grain deformation in the material. Robotic water jet platform offers significant capabilities in terms of flexibility, adaptability and control. This machine will be aimed at trimming of CFRP components and the capability will be researched for finishing and roughing operations.
5. Robots in Machining
As part of the COROMA (Cognitively Enhanced Robot for Flexible Manufacturing) project, a smart weld grinding solution which combines scanning, path planning, and machining and inspection capabilities on the same platform has been developed. The solution aims to minimise the human involvement in robotic machining by reducing the effort in part setting and programming and to ensure the part quality every time using an optimised machining approach and parameters.
This demonstration will also show a robotic mobile fixturing system. In aerospace industry, parts usually have very slender features and this may lead to chatter problems or unacceptable fom errors during machining process. A robot is utilized as a fixture to improve the dynamics stiffness of workpieces. The robot is integrated to the machine tool. Force control module is also developed for the robot.
6. CO2 Assisted Machining
CO2 assisted machining is an environmentally friendly alternative to conventional machining. A sustainable cooling approach to improve component surface integrity is being developed. We are aiming to lower tensile stresses to reduce the risk of stress corrosion cracking in the nuclear components and also cleanliness. The components do not have to be additionally cleaned, less energy is used for cooling. There is no hazardous waste to dispose, and no wet chips. Our demonstration will show a high feed milling of stainless steel with assist of supercritical CO2 + MQL as coolant.