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Software Development from Theory to Practical Machining Techniques

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Software Development from Theory to Practical Machining Techniques Software development from theory to practical machining techniques Khashayar Shahrezaei Pontus Holmström Mechanical Engineering, master's level 2020 Luleå University of Technology Department of Engineering Sciences and Mathematics Abstract In already optimized processes it may be challenging to find room for further improvement. The solution can be found in the advanced software and tools that support the digital manufacturing, all the way from planning and design to in-machining and machining analysis. This project the- sis focuses on developing a process methodology to transcribe Sandvik Coromant's theories and knowledge about machining operation grooving into machine-readable formats. Various software development models have been analysed and a particular model inspired by the incremental and iterative process model was developed to match the context of this project. This project thesis describes the working methodology for gathering theories and translating them into machine-interpretable format. A working methodology developed in this project thesis succeeded in transcribing different human- readable theories such as people's minds (experts within the field) and handbooks into a machine- interpretable format. The proposed algorithms for tool path generation was developed and imple- mented successfully through the integration of mathematical modelling. MATLAB R and Siemens NX has been used to build a proof of concept environment. Acknowledgements This report is created in our thesis work and as the last step in our Master of Science education in Mechanical Engineering at the Lulea University of Technology. We would like to thank our supervisors from Sandvik Coromant, Marko Stugb¨ak,Fredrik Selin, Pontus Westlin and Stefan Wernh for their guidance and encouragement in our work. Their knowledge and experience in the field have been very helpful in the discussion and planning of our research as well as in its execution. We would like to thank Sanvik Coromant in Sandviken for giving us the opportunity and their reflections on our work. Khashayar Shahrezaei Pontus Holmstr¨om Lulea, June 2020 ii Contents Abstract i Acknowledgements ii Abbreviations v Designations vi 1 Introduction 1 1.1 Sandvik Coromant....................................1 1.2 Background........................................1 1.3 Problem Definition....................................2 1.4 State of Art........................................3 2 Theory 6 2.1 Software Development Models..............................6 2.1.1 Waterfall model.................................7 2.1.2 Incremental and Iterative model........................8 2.1.3 Spiral model...................................8 2.2 Cutting parameters....................................9 2.3 External grooving..................................... 10 2.3.1 Roughing..................................... 12 Multiple grooving............................. 12 Plunge turning.............................. 13 2.3.2 Finishing..................................... 14 2.4 Insert design....................................... 14 2.5 Numerical Control Code (NC).............................. 16 3 Methodology 17 3.1 Planning.......................................... 17 3.1.1 Time and resource planning........................... 17 3.1.2 Functioning analysis............................... 17 3.1.3 Design....................................... 18 3.1.4 Implementation.................................. 18 3.1.5 Testing...................................... 18 3.2 Software domain..................................... 18 3.2.1 Component module............................... 19 3.2.2 Tool selection module.............................. 20 iii iv 3.2.3 Tool path generation module.......................... 22 3.2.4 CNC code generation module.......................... 22 3.3 Proof of Concept..................................... 23 3.3.1 MATLAB App Designer............................. 23 3.3.2 NXOpen...................................... 23 4 Results and Discussion 27 4.1 System and User Requirement.............................. 27 4.2 Domain Model...................................... 29 4.3 Tool path generation................................... 30 4.3.1 Multiple grooving................................ 33 4.3.2 Plunge turning.................................. 38 4.3.3 Finishing..................................... 45 4.3.4 NC-code...................................... 49 4.4 Proof of Concept..................................... 49 4.4.1 MATLAB R application............................. 50 4.4.2 NX application.................................. 51 4.4.2.1 Block dialogue............................. 51 4.4.2.2 Template code............................. 53 4.4.2.3 Simulation samples.......................... 54 5 Conclusions and Future work 56 5.1 Overview......................................... 56 5.2 Future Work....................................... 57 A Insert assortment 59 B Finding suitable multiple grooving method 60 C Overall interaction workflow of the Block Dialog and template code. 63 D External Grooving Application/Software 65 Bibliography 70 Abbreviations S.C. Sandvik Coromant CAD Computer Aided Design CAM Computer Aided Manufacturing POC Proof Of Concept API Application Programming Interface IGES Initial Graphics Exchange Specification STEP STandard Exchange of Products NC Numerical Control CNC Computer Numerical Control OH Over Hang CR Corner Radius CW Cutting Width CRP Cutting Reference Point GM Grooving Medium GF Grooving Finishing GR Grooving Roughing TM Turning Medium TF Turning Finishing v Designations OH Overhang [mm] δ Bending parameter [mm] F Axial force [N] h Holder height [mm] t Holder thickness [mm] CW Insert cutting width [mm] CR Insert corner radius [mm] REL Insert corner radius left [mm] RER Insert corner radius right [mm] AP MX Insert maximum depth of cut [mm] CDX Maximum cutting depth [mm] SC Stock clearance [mm] DMS Diameter machined start [mm] DME Diameter machined end [mm] CRL Component corner radius left [mm] CRR Component corner radius right [mm] W Full Width groove [mm] W(R) Width groove roughing [mm] Ws Width of steps [mm] RA Difference of insert and component radius [mm] Hs Height of steps [mm] d Full depth groove [mm] d(R) Depth groove roughing [mm] ap Cutting depth [mm] apnew New cutting depth [mm] apz Finishing axial cutting depth [mm] vi vii apx Finishing radial cutting depth [mm] vc Cutting speed [m/min] fnz Feedrate axial direction [mm/rev] fnx Feedrate radial direction [mm/rev] Xtop Top boundary [mm] Xbottom Bottom boundary [mm] Xcl Clearance in x-direction [mm] Zleft Left boundary [mm] Zright Right boundary [mm] Zloc Location of groove [mm] Zcl Clearance in z-direction [mm] Pf Number of full width cuts [-] Pt Total number of cuts [-] k Direction value [-] i Iteration number [-] n Amount [-] Chapter 1 Introduction 1.1 Sandvik Coromant S. C. (Sandvik Coromant) is a part of global industrial engineering group, Sandvik. Sandvik Coro- mant is at the forefront of developing manufacturing tools and machining solutions, with knowledge that drives the industry standards and innovations demanded by the metalworking industry now and in the next industrial era. Collaborations with educational institutions, extensive investment in research and development and strong partnerships with customers support the development of advanced machining technologies and systems that will change, lead and drive the future of man- ufacturing. Sandvik Coromant owns over 3100 patents worldwide, employs over 8,000 staff, and is represented in 130 countries. 1.2 Background The interests of migrating the analog knowledge or data into the digital platform are more in interest for companies providing technologies for different markets across the world. S. C. is one of the leading companies that is participating in these digital transformations. The software CoroPlus R Tool Path provided by S. C. is a digital solution for smarter machining solutions. CoroPlus R Tool Path supplies and generates correct NC programming codes and machining tech- niques for various applications [1]. CoroPlus R Tool Path is specially designed to provide a correct tool path and also at the same time optimizing cutting data. The result will be optimal produc- tivity, tool life, and process security[1]. 1 2 Implementing the best practical knowledge into S. C.'s software CoroPlus R Tool Path, where the customers can customise input parameters and overcome challenges and minimise the waste of resources, time and data to ultimately become more profitable. S. C. is continuously working on making its products sustainable, which delivers quality and durability. S. C believe in high quality products which leads into long-lasting customer's experiences which results in devotion to the company. Besides the quality of their products, another important factor that affects the duration of their products, is how the tool is used in machining. S. C. has for a long time through research and testing gained knowledge of the optimal ways to use metal cutting tools in order to make them last as long as possible. A way of sharing this knowledge to their customers is with their software CoroPlus R Tool Path where the customers have easy access to an optimal tool path e.g. Which will improve the tool's durability and therefore will result in satisfaction with the customer. S. C. have already a few machining techniques implemented into CoroPlus R Tool Path such as PrimeTurningTM and Threading [1]. Increasing the number of digital machining operations within the CoroPlus R Tool Path
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