In this paper, an optimal Electrical Cam (Ecam) profile is obtained by identifying the best breakpoint positions for piecewise polynomials using the cubic spline interpolation method. To achieve a curve that best tracks the reference Ecam curve, the breakpoint positions are determined using particle swarm optimization with random inertia weight (RNW-PSO). The previous programmable logic controller (PLC) used in the sanding mechanism was the DELTA DVP40ES2, utilizing the Ecam capability of DELTA ASD-A2 servo motors. To implement the Ecam function independently of the servo motor type, it has been integrated into a PLC, specifically the SIEMENS SIMATIC CPU 1215C. The optimized Ecam curve is then applied to a computer numerical control (CNC) sanding machine. Practical results demonstrate the effectiveness of the proposed method, showing improved sanding quality and better compliance with the reference curve.

The accuracy and precision of computer numerical control (CNC) machine tools directly affect the dimensional accuracy of machined parts. Accurate detection of machine tool errors with respect to positioning and orientation is imperative to the accuracy of the manufacturing process and, further, to eliminate errors through error compensation techniques. This paper presents a method to measure and determine angular errors resulting from drive axis out-of-straightness. Measurement of errors in discrete steps has been carried out via laser autocollimator and the method of neural networks (NN) has been employed to predict the amount of errors in the range between the steps. The results from this study can be used as a model for industrial applications to identify errors prior to the programming of the manufacturing process.

Meanwhile damages on machine, the created vibrations during the machining process will effect on the significant results of the process, such as surface finishing.6ptimized design of the machine tool and high quality of the workpiece would be possible by determining the vibration characteristics of machine structure. In this paper, transient and harmonic dynamic behavior of gantry CNC milling machine (DMC 1000) has been studied. For this reason, rudimentary structure of the machine and its main complex are modeled in the commercial Solidworks software. Then, the natural frequency and dynamic response are evaluated in both transient and harmonic moods using ABAQUS.Finally, the stability condition is investigated for the current machine. Results showed that the system response is more sensitive under frequency of 400 Hz and the largest displacement occurs at first locating position of spindle.

In this research, an effort has been made to examine and evaluate the impactful forces on a simple and cost-effective rail system, which has been modified by the addition of a suspension system. The studied rails are part of a specialized machine designed for producing lightweight wooden components with a similar pattern. This mechanism comprises two shafts and four linear bearings, ensuring smooth and error-free sliding along the shafts. All loads and forces related to other perpendicular axes are concentrated on this rail system. Consequently, through the design and incorporation of a suspension system into this setup, the adverse effects of forces on the rails have been ameliorated and significantly reduced compared to the previous state. The influence of the suspension system on the axis has been assessed using MSC ADAMS software, with results demonstrating a substantial reduction in the range of oscillatory forces originating from machining operations on the shaft.

Polishing is considered as the last and most important step in the manufacturing of optical components. Computer control polishing (CCP) methods are usually used to polish complex surfaces. In this method, material removal is controlled at each point, depending on error at that point. In contact polishing mechanism, tool feed rate is often controlled to eliminate local errors. It means that the higher the tool feed rate, the lower the material removal would be and vice versa. Tool influence function (TIF), which is defined as the instantaneous material removal under the polishing tool for a given tool motion, is the most important parameter in CCP and its predictability during the polishing process leads to reliable result. In this study, a new spherical tool which can polish complex surfaces by using a 3-axis CNC machine is presented. Because of spherical geometry of both tool and work piece, tool, material removal rate is variable because of changing the angle between tool axis and surface normal vector which leads to variation of relative speed. Tool influence function which depends on tool engagement’s angle was modeled based on Preston equation. Moreover, the simulation is modeled based on discretization of tool path. To evaluate the methodology, some polishing experimental tests were performed. The experimental results show that a 130 mm spherical convex lens with initial surface roughness of 1.114 micrometer for PV was decreased to 395 nm for PV using the CCP method developed in this study.

In the use of numerical control machines, offline setup has been possible by using a variety of software applications in the field of modeling and machining without the need to execute a process by the machine. Therefore, many decisions can be made before the machining process. The machine vision is considered as one of the technologies that can be used for offline setup of the workpiece which located on CNC machine tools before machining operations. In this research, this method has been used to determine the position of two casted part samples on a CNC milling machine. The mean error after 10 times testing in order to finding a circular center of Some kind of casted cap as workpiece origin includes 0.361 mm along the x axis and 0.372 mm along the y axis and the mean error of finding the workpiece origin of the casted pump impeller was 0.2 mm. Also, mean error for finding edge location of the molded cap in order to reduce the time for determining the movement direction of the tool relative to the workpiece which is clamped on the machine tool table, includes 0.25 mm in both x and y directions, and 0.4 mm along the z axis. The model error recovered from the extracted points were obtained by processing the images of the casted pump impeller to determine its position includes 0.363 mm in all three directions x, y and z.

The poly-ethylene model of a hexapod table with six degrees of freedom has been developed by the authors on the basis of Stewart-Gough mechanism. A conventional CNC milling machine can be converted into a six axis machine by installing the hexapod table in place of the table of the machine. The axial forces of the struts and their changes have been investigated with the table center situated at its most critical position .The diagrams illustrating these changes can be employed to decide the workspace involving minimum axial forces in the struts for specific machining conditions and placement of the spherical and universal joints. The analytical results have been verified with the experiments carried out on the model.

Error compensation using software methods is an effective and low-cost solution for increasing machining accuracy in CNC machine tools. In current research, the main goals are to develop a method for measuring geometric error, modeling, and geometric error compensation for the Rotary table of a 4-axis machine tools by implementing Homogeneous Transformation Matrix (HTM) method. After designing parametric-error model, empirical data is experimentally obtained, required for calculating unknown parameters of the model. Then, data measurement tests were carried out by a BallBar Measurement mechanism according to ISO 230-7 standard on the four-axis CNC milling machine. BallBar mechanism can measure the movement deviations of a constant radius circular path for different directions. After substituting experimental data in the proposed error model, by using matrix and computational relations the complete error model of the process is achieved. Finally, geometric errors for different angles of the rotary table are extracted from the error model and presented. Among achievements of this research, the new error model and the method of verification could be mentioned. Based on the validated model, compensations on the tool path can be carried out in order to reach higher accuracy. In addition, the error compensation method used for equipment installation, and the type of movement selected for BallBar mechanism on the 4-axis machine tool, will elevate the precision and accuracy of results. From the innovative outcomes of the present study, optimum error model and its validation to investigate the consistency of the results in both empirical and theoretical approaches is absolutely worth mentioning.

CNC machine tools are widely used to produce precise parts through executing expensive operations. In precision machining, the machine tool's geometrical and kinematical errors cause geometrical and dimensional deviations in vital features of machined parts. Kinematic modeling of a machine tool structure can help to predict the real value of the overall tool positioning error. In this paper, modeling of three-axes CNC machine tools has been considered. The developed model can simply be used for all kinds of linear axes configurations, like three-axes CNC machine tools. The model can be useful for a large variety of applications, including software based error compensation systems and prediction of the real shape of parts after being machined or measured by error contained CNC or CMM machines. Experimental tests were conducted to validate the model. Analytical estimations were shown to be in good accordance with experimental tests.