Dynamic Analysis of Helical Milling Unit Based on Virtual Machine Tool

Sensor Data and Information Fusion to Construct Digital-twins Virtual Machine Tools for Cyber-physical Manufacturing

In order to cope with the increasing functionality of today's machine tools, software development for programmable logical controllers (PLC) needs systematic approaches for testing implemented routines. An automatic test machine executing test runs as workflows is able to fulfill the given requirements. A prototype, developed at Laboratory for Machine Tools (WZL) of RWTH Aachen University, combines mechatronic development with a virtual machine tool. With its help, PLC software and simulation models can be generated basing on a meta-model that allows an integrated engineering of software and functionality. It is thus possible to test software parts automatically and without need for a (real) machine tool.

Scheduling flow shops in the environment of multi-functional machine tools

A blowout preventer (BOP) is a large valve that encases an oil well on the surface. The valve may be closed while drilling if overpressure from a reservoir causes formation fluids such as oil and natural gas to back up within the wellbore and endanger the rig. A pipe ram is one of the critical components in the BOP system, which is designed to seal around a drill pipe, restricting the flow in the annulus between the outside of the drill pipe and the wellbore. The pipe ram design family, which contains hundreds of pipe ram designs, intends to cover different configurations to suit a variety of dill pipe sizes. To assure their structural integrity under service loads, these pipe rams need to be designed to meet the stress requirements per the American Petroleum Institute (API) Specification 16A and ASME (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section VIII, Division 2. With a conventional manual design workflow, it would take a significant amount of time and effort to complete all the designs for the product family with code compliance. Therefore, a scalable solution is highly desirable for delivery of customer-needed ram blocks with much shorter lead time. MDO (Multi-Disciplinary Optimization) involves multi-code integration, CAE (Computer-Aided Engineering) workflow automation, design space exploration, and optimization. MDO-enabled, automated design optimization is becoming increasingly popular in both scientific and engineering communities. In this paper, a methodology for integration of CAD (Computer Aided Design), FEA (Finite Element Analysis), cost, and optimization packages to enable FEA automation and design optimization is presented. A BOP pipe ram is adopted as the use case. The ram block geometry was parameterized before being imported into an FEA package. The FEA workflow was automated such that once a set of geometric parameters are given, the preprocessing, solving, and postprocessing steps can be automatically completed. As part of the FEA postprocessing, stress linearization analysis per the API and ASME BPVC codes has also been automated, which had never been done in the past. A manufacturing cost analysis package can also be used to consume the parameterized geometry for automatic manufacturability assessment and cost predictions. The stress analysis and cost analysis workflows are conducted separately but also orchestrated by an MDO package. Reports that contain the analysis results are sequentially generated for various design permutations. The MDO-enabled automated design and cost analysis approach could substantially enhance efficiency and consistency in performing FEA and cost studies and producing analysis reports. It is also the backbone for automated design optimization, which could significantly improve the product performance and reliability and, meanwhile, minimize the development and product cost.

Micromechanical gyroscope is one of the important applications of attitude control platform and inertial navigation system. However, domestic gyroscope research and development is not highly integrated at present, and the main research focuses on the design of micro-gyroscope with a single detection axis (especially z-axis detection). In order to realize the monolithic triaxial gyro which can be used in the field of intelligent ammunition, a wheel ring gyro structure is designed. The gyro structure was modeled on the SolidWorks software, and then modal analysis, transient impact response analysis and harmonic response analysis were carried out in the finite element analysis software ANSYS respectively. According to the natural frequency of each mode, the structure size of the gyroscope is optimized. Through the simulation results, it is observed that the frequency split between the working modes is relatively small, and the structure has high mechanical sensitivity. The transient impact simulation of the gyro structure shows that the maximum stress of the sensitive structure under the impact of 10000g@5ms is 394.34Mpa, which proves that the structure has good impact resistance.

Model updating is concerned about the correction of finite element models by processing the record of dynamic response from test structures in order to have an accurate model for any simulated analysis. Finite element model updating had emerged years ago as an important subject in structural dynamics. It has been used frequently and has been successfully applied to many fields especially in detecting the dynamic stiffness of a structure. The purpose of this study is to perform model updating of a go-kart chassis structure in order to reduce the percentage of error between the experimental modal analysis (EMA) and finite element analysis (FEA). Modal properties (natural frequency, mode shapes, and damping ratio) of the go-kart chassis structure were determined using both EMA and FEA. Correlation of the modal parameters gathered in FEA and EMA was carried out before optimizing the data from finite element. By adjusting the selective parameters, incongruities between those two analyses are generally reduced. The sensitivity of selected parameters is also obtained. The significant reduction in percentage of error before and after model updating procedure was carried out in this study clearly shows that model updating technique is a reliable method in reducing the discrepancies between EMA and FEA. Therefore, in cases of high discrepancies between analytical and actual test data, model updating can be considered as an option in order to obtain better correlation between those two sets of data.

The disc brakes are exposed to large thermal stresses and heat during routine braking. The extraordinary thermal stresses, tremendous heat occurred in the disc during hard braking. The aim of the project or research work is to design and analysis of disc. The modelling or design of the disc is done using solid works software. The Thermal analysis is to be done on the Non-vented disc brakes using ANSYS software with different materials. The thermal analysis is done to analyze the thermal properties e.g. Thermal deformation. Comparison can be done for temperature distribution between different materials. In this analysis, different materials to check which material are best. Solid works is a 3d modelling software widely used in the design process. The ANSYS software is general-purpose finite element analysis (FEA) software package. Finite Element Analysis is a numerical solution method of deconstructing the complex system into very small pieces called elements. Keywords – Rotor brake, solid works, structure and thermal analysis, ANSYS.

The primary goal of this study is to develop a wearable system for providing CNC machine operators with visual and tactile perception of triaxial cutting forces, thereby assisting operators in industrial environments to enhance work efficiency and prevent mechanical failures. To achieve this goal, we successfully integrated a virtual machining tool simulator with the remote-control wearable system (RCWS). Using the ‘King Path’ milling parameters, we employed the simulation software developed by the AIM-HI team to calculate static and dynamic cutting forces, converting this data into vibrational commands for the RCWS to generate corresponding tactile feedback. Furthermore, we conducted extensive experiments, testing various data conversion methods, including three sampling techniques and two data compression strategies, aiming to provide accurate tactile feedback related to cutting forces under different operating conditions.

Switched reluctance machine (SRM) has a simple and low cost construction owing to the concentrated windings on the stator, no permanent magnets or windings on the rotor. This rugged structure offers many advantages such as high speed, fault tolerant and reliable operation, wide constant power range, low inertia and low inrush currents. However, due to the single source of excitation and dependence of inductance profile on excitation current and rotor position, the mathematical model of SRM is highly nonlinear. Moreover, unlike many other electrical machines, the energy conversion capacity of SRM is greater when working under high magnetic flux densities. In case of SRM with higher number of rotor poles, stator and rotor pole arc angles are limited due to the smaller interpolar gap. Therefore, it's harder to adjust the dimensions of the machine to prevent high saturation at the poles. Considering the nonlinear behavior and design challenges with the higher number of rotor poles, an iterative process is necessary for an SRM design and finite element analysis (FEA) software are widely used to get the inductance and torque profile for the given dimensions. The performance of an SRM is also dependent on torque ripples, which is a function of turn-on and turn-off angles. These parameters cannot be calculated in FEA, because it requires the dynamic control of the phase currents according to rotor position. This paper proposes a MATLAB based design tool, which, for the given machine dimensions and parameters, calculates the geometry and automatically draws and simulates the machine model in FEA software. Moreover using those results, it performs a dynamic simulation in Simulink plots the load torque and phase current profiles and so manages the whole design process. The geometrical and electrical design equations are given and the graphical user interfaces of the design tool are introduced.

This study aimed to assess the impact of different thermoplastic gutta-percha obturation techniques on periradicular tissue temperature changes in maxillary central incisors with simulated internal resorption cavities using finite element analysis (FEA). A human maxillary central incisor extracted for periodontal reasons was scanned using a micro-computed tomography device (SCANCO Medical AG, Zurich, Switzerland). Internal root resorptions were designed in the coronal, middle, and apical regions on the solid model using SolidWorks software (SolidWorks Corp., Waltham, MA, USA). The resorption areas were filled using two different thermoplastic gutta-percha techniques: continuous wave condensation (CWC) followed by backfill (BF) techniques, carrier-based gutta-percha (CBG) techniques. The models were also classified based on the presence or absence of simplified blood-flow layer (100 μm) representing perfusion in the periodontal ligament and then transferred to ANSYS software (Canonsburg, PA, USA) for FEA. Consequently, 16 different tooth models were created. Higher temperature values were observed in the apical resorption of the apical third region compared to other regions for both obturation techniques. The CWC + BF technique resulted in higher temperatures and longer durations above the critical threshold of 47 °C compared to the CBG technique. Simulated blood flow reduced PDL and bone temperatures in all models. Under these modeled conditions, the CBG technique induced less periodontal heating than CWC + BF, while apical resorption presented the greatest thermal risk. Experimental validation and advanced bioheat perfusion modeling are required before clinical extrapolation.

Finite element analysis (FEA) software is utilized to simulate and evaluate a conventional steel resolver and a 3D printed resolver (material: acrylonitrile butadiene styrene). Moreover, the magnetic flux density distribution of the resolvers is presented by the FEA software. The performances of the resolvers are discussed in time domain and frequency domain. Furthermore, a test bench is set up to prove the capabilities of resolver system.

Design by analysis is usually performed by commercially available finite element analysis (FEA) software. Constitutive models available in the FEA software are developed and validated using limited experimental data. Hence, a broad set of thermomechanical fatigue experiments with strain dwell at compressive peaks are performed to understand local fatigue failure responses of high temperature components. This study developed a unified viscoplastic model based on nonlinear kinematic hardening of Chaboche type with added features of strain range dependence, rate dependence, temperature dependence, static recovery, and mean stress evolution. The robustness of the constitutive model is demonstrated by comparing its simulations against the experimental responses.

In this study, 4 different pieces of automotive rear lamp lenses which are made of Polymethylmethacrylate (PMMA) and have different geometries have been inspected. Free-free natural frequencies and mode shapes of lenses have been estimated by the help of ANSYS WB® Finite Element Analysis (FEA) software. Meanwhile, by the help of Experimental Modal Analysis (EMA) methods; natural frequencies, damping ratios and mode shapes of the lenses have been determined. Finally, mode shapes calculated by FE and measured by EMA were compared and Modal Assurance Criteria matrix (MAC) was determined. After experimental modal tests, FRF’s were calculated by DEWESoft® X3 software then natural frequencies, damping ratios and mode shapes were calculated by the use of ME’scope® VESVT-570 Visual Modal software. In addition, MAC was calculated by the help of MEScope® software. The main reason for the use of such experimental methods was to understand if the assumptions made before theoretical analysis were satisfied in reality or not.

Purpose, with the application of workbench finite element analysis software, get the analysis results of DVG 850 high-speed vertical machining center via the modal analysis and harmonic response analysis. Use the calculation results for reference, put forward the improved method, and prove the credibility of the simulation analysis by testing DVG 850 prototype.

In this paper, a 5-DOF serial-parallel manipulator with RP-(2-RRU/1-RUU) structure is proposed. This manipulator is used to the automatic production line, to complete the materials' loading, delivery and unloading. In order to ensure the safety and high efficiency production, the manipulator has good stiffness and high accuracy, and is suitable for the fast operation. Based on the above requirements, the manipulator has the big work space characteristic of the serial mechanism and the high precision and stiffness characteristic of the parallel mechanism. However, the difficulty of its dynamics analysis is increasing. In this paper, the modal analysis and the harmonic response analysis are carried out using finite element analysis software, and the dynamic characteristics of the manipulator are derived. The inverse dynamics modeling has been performed based on the Newton-Euler method. The dynamics simulation is carried out to check the correctness of dynamics modeling. This study is also significant to the trajectory planning and control system.