Abstract

This study was carried out to investigate the relationship between advanced technology CNC that we
combined from 7 journal that we have it.. Advanced Manufacturing Technology (AMT) is the
application of the latest scientific or engineering discoveries to the design of operations and
production processes. Computer Numerical Control (CNC) technology has been playing an important
role in the manufacturing industry since it was first developed in early 1950’s .CNC milling, lathing,
grinding, drilling and cutting machines are found in almost every sector of the industry. These CNC
machine tools are especially useful to
machine the parts with complicated shapes in the industries such as aerospace, automobile, mold
fabrication, and equipment building. The paper describes a new CNC control unit for machining
centres with learning ability and automatic intelligent generating of NC programs on the bases of a
neural network, which is built-in into a CNC unit as special device. The device performs intelligent
and completely automatically the NC part programs only on the bases of 2D, 2,5D or 3D computer
model of prismatic part. Intervention of the operator is not needed. The neural network for milling,
drilling, reaming, threading and operations alike has learned to generate NC programs in the learning
module, which is a part of intelligent CAD/CAM system. Intelligent, agile manufacturing relies on
automated programming of digitally controlled processes. Currently, processes such as Computer
Numerically Controlled (CNC) machining are difficult to automate because of highly restrictive
controllers and poor software environments. It is also difficult to utilize sensors and process models
for adaptive control, or to integrate machining processes with other twithin a factory floor setting. As
part of a Laboratory Directed Research and Development (LDRD) program, a CNC machine control
system architecture based
on object-oriented design and graphical programming has been developed to address some of these
problems and to demonstrate automated agile machining applications using platform-independent
software. Purpose the work presented in this paper might be used for basic data in the design of a lot
extruded aluminum products using the variable section extrusion
process.Design/methodology/approach the capacity of a CNC extruder was calculated and decided as
analyzing the FEM results performed by commercial software DEFORM-2D. CNC extruder and die
set for variable section extrusion was invented by field extrusion experts. Findings CNC extruder had
a key role in variable extrusion process. Furthermore there was few die sets with mold feeding parts
for aluminum extrusion. To be capable of extruding aluminum products with variable cross section
are CNC extruder and the die set.
A new approach for defining and machining intricately shaped curved surface parts is presented. The
surface is defined by triangular facets, the density and structure of which are determined by the
intricacy and form accuracy of the surface. Appropriate decimation and subdivision algorithms are
used with edge swapping to develop a uniform facet height deviation surface model.The CAM
software for drill grinding has been developed to save time, reduce cost for tool manufacturing and
obtain accuracy of tool. In this paper, the developing software for drill will be presented including
calculation and simulation of machining processes using 5-axes CNC grinding machine. The
algorithm for helical flute grinding was applied into calculating NC data. The software will generate
NC code for machining by using input data of tool geometry, wheel geometry, wheel setting, machine
setting. These NC code files will be used in simulator as input file. The simulator provides some
functions for simulating machining processes, inspecting and measuring tool geometry.

Introduction

Design information such as engineering drawing can be stored in various kinds of CAD systems.
However, the CAD systems often represent the data in many ways and in different formats. Spanner’s
design has been used as a case study and it is produced through CAD software (Solid Works
2007).STEP (Standard for the Exchange of Product model data) still carries much redundancy
information, which is not necessary to RP systems.
The STL (Stereo Lithography) file is the most common interface between CAD and RP systems. The
STL file can be in either ASCII or binary format.IGES (Initial Graphics Exchange Specification) is a
standard used in the exchange of graphics information between commercial CAD systems. Many
advantages as an interface between CAD and RP systems.
VRML (Virtual Reality Modelling Language) that contain less redundant data when compared with
STL files and contains all the features of STL. Use in colour RP systems and can store the
geometric.VDAFS (VDA Surface Data Interface) is a neutral file format for the exchange of surface
geometry. Defined to eliminate the deficiencies of the CAD interface IGES.Eight different points has
been determined to make a comparison for each format files because their design complexities such as
fillet, edge, and engrave.

Variable section extrusion process

The variable section extrusion process is a new process that changes the section of the extruded
material by using the mould moving in the direction perpendicular to the direction of extrusion during
the general extrusion process that extrudes rods or tubes.
It will be effective for the commercialization and cost reduction of a new raw material, such as
aluminum, whose cost is relatively high compared to Fe-based material, by eliminating the successive
processes (hydro-forming and bending). It is more advantageous compared to the existing sub-frame
manufacturing process. This variable section extrusion process is used as a base for the reduction of
the number of processes as well as integration of new processes to produce aluminum parts with low
production cost and high reliability.

Design of CNC Variable Section Extruder

Unlike general extrusion processes, in the case of the variable section extrusion process, the section of
extruded material is changed during extrusion. Therefore, the extrusion speed and the mold moving
speed perpendicular to the direction of extrusion must be adjusted and synchronized within certain
range during extrusion. Particularly, since this equipment used for this study is manufactured to
examine major parameters of the process and equipment for future commercialization of variable
section extrusion, it must be designed and manufactured to allow experiment at various speeds and
under various load conditions. Therefore, the system of equipment was configured so that the main
stem is controlled by the servo pump and the mold feeding is controlled by the servo valve. Major
variables that have influence on the accuracy of a product in general extrusion processes include
characteristics and temperature of the material, temperature of the mold, extrusion speed, mold shape,
lubrication condition, etc. Therefore, proper design for the mold and process is essential to produce
precision products. In addition to this, the variable section extrusion needs to consider, for example,
sliding part design according to movement between molds and thermal expansion due to temperature
difference since it moves one or more mold parts. Since the purpose of this study is to investigate
variables of the extruder, mold and process, as well as their influence, the mold was designed to have
a strong structure. Fig. 7 shows the structure and overall assembly drawing of the designed mold.

Intelligent computer numerical control unit

 The neural network for milling, drilling, reaming, threading and operations like this have
learned to generate NC part programs in system for learning, which is not a constituent part of a new
CNC control unit, and works independent.
The new control unit then completely automatically, without any intervention of the operator,
on the bases of a CAD model of a part, generate NC part programs for different products, which are
designed for the production on CNC machining centres and for which previously NC part programs
have not been done.
CNC control unit consists of a modified microcomputer, which includes a module for decoding and a
module for manual input of commands, which are mostly of technological nature (feed rate,
revolution speed, switch on/off of cooling liquid etc.). Computer includes also the internal interface,
which has the function of data transmission from the NN device into the position memory.

Schematic lay-out of NN device

 In the phase of learning the NN device is connected to the module for learning of the neural
network, which takes the data from the usual, commercial available CAD/CAM system, which is used
for programming of NC/CNC machine tools. NN device automatically generates NC programs for
CAD models of each individual product, which it becomes from the commercial CAD/CAM
programming system. CNC control unit after this invention can receive the data for teaching of NN
device from a special module for teaching, which is not the constituent part of the control unit. The
task of the module for teaching is to teach the neural network, which is built-in into NN device, the
principles and the technology of NC programming of all machining operations on CNC machining
centres, mostly milling, drilling and operations alike.
In principle for this purpose different systems of neural network and different, also commercial
developed software, can be used .If we want to meet special criteria at machining (costs, time, quality
of cutting, tool life, high speed cutting etc.) special developed neural network must be used.

Administrative technology

Administrative technology is a technology used to give administrative support to the factory

and integrate its operations with the rest of the organization. According to Adler, there are eight items
consist in this variable, which are: electronic mail, electronic data interchange, office automation,
knowledge-based system, decision support systems, material requirement planning (MRP),
manufacturing resource planning (MRP II) and activity based accounting systems.
Many researchers had differentiated the benefits of AMT into two types, which are tangible and
intangible. Ariss, Ragunathan, and Kunnathar (2000) supported this definition. The tangible benefits
which are easily quantifiable, include inventory savings, less floor space, improved return on
investment (ROI), and reduced unit costs. The intangible benefits which are difficult to quantify,
include an enhanced competitive advantage, increased flexibility, improved product quality, and quick
response to customer demand.
Siha and Linn (1989), Kaplan (1986) identified some of the potential benefits of advanced
manufacturing technologies that are similar to Ariss, Ragunathan, and Kunnathar (2000). The benefits
are:
a) Flexibility with respects to respond to changes in product, product mix, and volume
b) Compatibility refers to increased ability to be compatible with the existing (or future
options) of software, hardware and people.
c) Learning process refers to increased ability to gain experience with technology and to test
the market with new products.
d) Training refers to availability and good quality of training procedure for implementing a
complicated technology.
e) Quality refers to increased uniformity, consistency in product and easiness in product
testing.
f) Reliability refers to increased ability to ensure the continues flow of product;
g) Capacity refers to increased manufacturing throughout ability.
h) Inventory refers to reduced inventory size due to flexibility, shorter throughput and lead
times, and improved process flow, and improved quality (reduced rework scrap-waste
material) throughput and lead times refers to reduction in time to finish product and process
design, to manufacture, and to ship.
i) Safety refers to increased ability to avoid injuries and death accidents.
j) Floor space refers to reduced spaced requirement due to reduced inventory level, improved
quality, and cutting down large numbers of conventional machines by fewer numbers on
computer-controlled machines.

Intelligent automatic mode

In the mode of intelligent, completely automated processing the CNC control unit receives the data
about CAD model of the product from the usual, commercially available CAD/CAM system for
programming of CNC machines .The model is then transmitted to NN device, which first of all
recognizes geometric and technological features of CAD model of the part .After recognizing the
geometric and technological features are classified. On this way the new CAD model of the part is
built again, which is now based on this characteristic features. Such model is then transmitted to NN
device for milling, which on the base of learned intelligent procedures determines the most suitable
machining operations and cutting parameters (cutting speed, feed-rate and the depth of cutting.
The exit from the NN device for milling is NC part program for the processed part, which includes all
geometric data about the mode (linear G01 or circular G02/G03 interpolation, etc.) and coordinates of
cutting tool path (for instance milling cutter), technological data (revolution speed Sxxxx, feed-rate
Fxx, depth of cutting) and auxiliary data (coordinates of reference, zero and starting points, direction
of rotation of the main spindle M02/M03, change of cutting tools M06, etc.).
Split the data in NC program on tool path data (coordinates of movement in axis X, Y, Z and/or
rotation A, B, C around coordinate axis X, Y, Z and on data about functions (M, S, T).
The geometrical data are obtained from the NC part program for each individual part and are treated
in the position control circuit.

GiCNC system

The GiCNC control software can be divided into three structured layers. Top Layer: Man-Machine
Interface,Simulation, Editor, Handwriting Input,etc.Middle Layer: Compiler,Machinecommand
queue, Motion planner,Motion execution, Signal process,Feedback control, etc.Bottom Layer:
Motion controller,Analog/Digital I/O, etc.

Manual Operation Mode: In this mode, manual machine operations can beperformed, which
provides equivalent manual operation functions of conventional CNC machines. Thefollowing manual
operations can beperformed in this mode:
i)Machine homing and home return of
the machine sliding table
ii)Rotate handles to move manually the
machine sliding table
iii) Control the spindle speed
iv)Turn coolants, laser beam on/off
v)Make a simple marking/cutting
vi)Other misalliance manual operations

Auto Operation Mode: In this mode, a CNC program can run automatically. The execution of a
CNC program can bestopped or paused. Current status of the machine, tool position and executing
commands are displayed on the screen. Dry run, simulation and 3D-profile scan functions can also be
performed in this mode.

Editing Mode: CNC program and parameter file loaded in the PC memory can be edited in this
mode. Many editing functions can be performed, including insert, delete, mark, cut, copy, paste ,save,
and etc. Additionally, new features of Teach-In and Handwriting-Input are
developed. With the Teach-In feature, key points of tool paths can be input automatically by moving
physically the machine axes. By using the Handwriting-Input feature, strokes of handwriting can be
input automatically to the system and CNC programs can be generated for the purpose of handwriting
laser marking.
The compiler of GiCNC controller translates a CNC program into a queue of machine commands.
This queue of machine commands is stored into a special data structure called Command Queue. The
data structure of machine command queue (command queue for short) plays apivot role in GiCNC
controller. After a CNC program is translated into a
command queue, all the consequent processes will be carried out on the resultant command queue.

Test Bed for GiCNC: 3D Laser Marking System

Development of CAM software for drill manufacturing.

The Fig.1 shows the structure of developing software for tool grinding. In this study, the drill is
machined on 5-axis CNC grinding machine, which has 5 degrees of freedom: three axes in translation
(X, Y, Z) and two in rotation (B, C). Four kinds of grinding wheel are used for machining of drill.
Fig.2 shows configuration of 5-axis grinding machine for simulation of drill grinding processes.
Machining parameters including the machine setting parameter, drill geometric parameters, wheel
setting and wheel geometry must be measured and inputted into the program in advance.

5-axis grinding machine for simulation of grinding processes.

Conclusion
Unit solves the problem of automatic and intelligent generating of nc programs for cnc machining
centres. It describes the control device of a cnc machining centre for face milling (rough), contour
milling (rough), final milling after the contour and in z-plain, final contour 3d milling, contour final
milling, milling on z-plain, final contour milling on equidistant, milling of pockets, normal drilling,
deep drilling, centering, reaming, sinking and threading with the capability of teaching and automatic
intelligent generating of nc part programs on the bases of neural network, which is built-in into a
special nn device. The neural network for milling, drilling and operations alike can learn to generate
nc part programs in module for learning. The device then completely automatically, without the
intervention of the operator, only on the bases of 2d, 2,5d or 3d computer model of prismatic part,
which has not been previously programmed, generate nc part programs. In solving the machining
problems, the nn can serve as ideal tool, for helping nc programmer making the right decision, or at
least serve as an orientation tool. Time saving could be also achieved, because not so many post-
machining operations would be necessary.

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Conclusion

Unit solves the problem of automatic and intelligent generating of NC programs for cnc machining
centres. It describes the control device of a CNC machining centre for face milling (rough), contour
milling (rough), final milling after the contour and in z-plain, final contour 3d milling, contour final
milling, milling on z-plain, final contour milling on equidistant, milling of pockets, normal drilling,
deep drilling, centering, reaming, sinking and threading with the capability of teaching and automatic
intelligent generating of NC part programs on the bases of neural network, which is built-in into a
special NN device. The neural network for milling, drilling and operations alike can learn to generate
NC part programs in module for learning. The device then completely automatically, without the
intervention of the operator, only on the bases of 2d, 2,5d or 3d computer model of prismatic part,
which has not been previously programmed, generate NC part programs. In solving the machining
problems, the nn can serve as ideal tool, for helping NC programmer making the right decision, or at
least serve as an orientation tool. Time saving could be also achieved, because not so many post-
machining operations would be necessary. This study has empirically identified four dimensions of
advanced technology that suited Malaysia manufacturing environment, namely Design Technology,
Manufacturing Technology, Administrative Technology, and Resource Planning Technology. The
emergent of another new identified factor of resource planning technology adds the knowledge of
managers for effectively managing their manufacturing operations. presents the development of CAM
software for drill manufacturing using simulator. The developing CAM software will be applied to
design and manufacture drill for predicting drill configuration before machining by using CNC
grinding machine. This study also designed and fabricated a CNC variable section extruder to realize
variable section extrusion, and confirmed the possibility of commercialization of the variable section
extruder and process from the experiment for variable section extrusion. This study designed and
fabricated the mold with movable parts for variable section extrusion, and examined the possibility of
variable section extrusion through trial extrusion.
The new control unit solves the problem of automatic and intelligent generating of NC programs for
CNC machining centres. It describes the control device of a CNC machining centre for face milling
(rough), contour milling (rough), final milling after the contour and in Z-plain, final contour 3D
milling, contour final milling, milling on Z-plain, final contour milling on equidistant, milling of
pockets, normal drilling, deep drilling, centering, reaming, sinking and threading with the capability
of teaching and automatic intelligent generating of NC part programs on the bases of neural network,
which is built-in into a special NN device.