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This paper aims to investigate the performance and positioning accuracy of computer numerical controlled (CNC) feed drive system using a ball screw-based pre-loading impact factor.

Initially, axial displacement of support bearings has been computed in relation to the different preload values. Among the computed values, a basic rule equation has been developed for the calculation of elongation in the bearings. The value of displacements computed from the developed equation has been considered as a pre-loading value, and its behavior on the feed drive system has been analyzed.

The elongation of bearings impacts the positioning accuracy and repeatability of the feed drive system and of CNC machines. Next, an analytical model for the rigorous assessment of CNC feed drive system has been designed and developed. The positioning accuracy of CNC machine in relation with different pre-loading values has been analyzed.

The results obtained from these investigations enhance the positioning accuracy of CNC machining centers. The optimum pre-loading value has been analyzed among the available ranges, and it has been proposed that optimal results have been achieved at 5 per cent of dynamic load rating.

This paper proposes improved explorations toward the performance of the CNC machines by optimizing the positioning accuracy through pre-loading. Finally, analytical estimations have been carried out to prove the validity of the proposal.

For ball screw feed system, a sudden start or stop has a great influence on the transmission stiffness, so the axial stiffness mutation of feed system will occur. The purpose of this paper is to study the influence of acceleration on the transmission stiffness and dynamic characteristics of the ball screw feed system.

Taking the ball screw feed system as a research object, on the basis of the Hertz contact theory and the mixed element method, axial stiffness model and dynamic model are established. And the system stability was analyzed by the time history diagram and Phase-plane portrait diagram. The feed system was analyzed theoretically and experimentally, the experimental results are in good agreement with the model results.

Lead screw lead angle, preload, load and start acceleration affected ball-screw pair, bearing and transmission stiffness. And the load, nut contact stiffness, bearing contact stiffness, preload have a large effect on the transmission stiffness. The results show that a certain acceleration value will make the axial stiffness abrupt change.

This research provides a useful theoretical support for ensuring a good dynamic for the ball screw feed system.

Damage induced during drilling of polymer matrix composites depends upon torque during drilling. Modeling of torque with feed rate and its control becomes imminent for damage free drilling of composite laminates. Therefore, the purpose of this paper is to construct a transfer function between drilling torque and feed rate based upon experiments. Thereafter, the torque is controlled by using PID controller.

This paper presents step-by-step procedure to capture complex drilling dynamics of polymer matrix composites in a mathematical model. A glass fiber reinforced plastic (GFRP) composite laminate is drilled at constant feed rate during experimentation. The corresponding time response of torque is recorded. First order, second order and third order transfer functions between torque and feed rate are identified using system identification toolbox of Matlab®. These transfer functions are then converted into state-space models. Experimental verification is performed on GFRP composite laminate. PID controller is designed using Simulink® to track a given reference torque during drilling of polymer matrix composite. The controller is then validated using different reference torque trajectories.

Good match is observed between torque response from state-space models and experiments. Error analysis based on integral absolute error and integral squared error on experimental and simulated response show that third-order system represents the complex drilling dynamics in a better way than first and second-order systems. PID controller effectively tracks given reference trajectories.

Third-order model between torque and feed rate for drilling of composites not available in literature has been presented. PID controller has previously been applied successfully for drilling of conventional materials, this paper extends implementation of PID torque control for drilling of composites.

Although rework is labour intensive and conflicts with most modern manufacturing/assembly philosophies, realistic defect levels in surface mount technology (SMT) printed circuit board (PCB) assembly render rework indispensable on the shop floor. Most commercially available rework tools are manual or require very skilled operators for their efficient operation. The challenges of automating SMD rework are significant because the tools, their specifications and rework processes required are not fully understood, and the impact of rework processes on assembly quality and reliability are hotly debated. This paper describes an automated robotic rework cell for SMD and TH boards, and the method used for process characterisation of the solder paste dispensing system. The paper also describes equipment selection, the integration and interfacing of the dispensing equipment to the cell controller and the process characterisation experiments.

The alignment precision of existing methods is limited by the precision of detecting element and worker’s experience, which the parallelism between ball screw and guide way is not guaranteed effectively. Thus, this paper aims to propose a method of detecting ball screw’s alignment error (BSAE) via monitoring the average vibration magnitude induced by rotational frequency of ball screw (VMRFBS).

In this study, the ball screw is simplified as a freely supported beam. A mathematical model of the effect of BSAE on the contact angle of the ball and screw is established. The change of contact angle has effect on the deformation and contact stiffness according to the Hertz contact theory. To improve the accuracy of the experimental results, the VMRFBS are analyzed by using average method, and the average values of the VMRFBS at different BSAEs are calculated by using the least squares method.

The experimental results show that the average VMRFBS increases with the increasing of BSAE under the BSAE from 0 to 0.2 mm, while the other conditions are unchanged.

This method provides an approach to monitor the BSAE and improve the alignment accuracy of machine tools and automation equipment, which has a certain guide for improving the alignment accuracy of ball screw.

This study was conducted to analyze the effects of machining parameters on the specific energy consumption in the computerized numerical control lathe turning operation of a hardened alloy steel roll at low cutting speeds. The aim was to minimize its consumption.

The design matrix was based on three variable factors at three levels. Response surface methodology was used for the analysis of experimental results. Optimization was carried out by using the desirability function and genetic algorithm. A multiple regression model was used for relationship build-up.

According to desirability function, genetic algorithm and multiple regression analysis, optimal machining parameters were cutting speed 40 m/min, feed 0.2 mm/rev and depth of cut 0.50 mm, which resulted in minimal specific energy consumption of 0.78, 0.772 and 0.78 kJ/mm³, respectively. Correlation analysis and multiple regression model found a quadratic relationship between specific energy consumption with power consumption and material removal rate.

In the past, many researchers have developed mathematical models for specific energy consumption, but these models were developed at high cutting speed, and a majority of the models were based on the material removal rate as the independent variable. This research work developed a mathematical model based on the machining parameters as an independent variable at low cutting speeds, for a new type of large-sized hardened alloy steel roll. A multiple regression model was developed to build a quadratic relationship of specific energy consumption with power consumption and material removal rate. This work has a practical application in hot rolling industry.

To report on the design and development of a robotic automobile aluminium frame welding system.

The customer contracted with a team of suppliers, each with unique skills and products necessary for welding thin aluminium framing. The team employed simulation to help in the design process to avoid problems and to speed the time to complete.

Careful planning, detailed simulation and attention to details helped insure that working production systems was in service to meet a tight deadline.

Companies looking to develop welding systems for structures from aluminium or other materials can learn from the benefits of a team approach to complex application development. As the auto industry moves to more use of lightweight materials such as alumnus, successful automation of its welding will be ever widely appreciated.

Any user planning an automated aluminium frame welding system can learn from the success of Ford Motor and its welding system design partners. Careful planning and teamwork can help in meeting production and timetable goals.

Modern variable‐speed drive systems using frequency converters generate additional audible noise as a result of the voltages that are no longer sinusoidal. Using suitable measures, the purpose of this paper is to find an optimum for minimum noise radiation in the complete drive system.

The main areas to concentrate on to achieve an optimum are the source of excitation itself – the frequency converter, as well as the actual source of the noise, the motor. Optimization measures are drawn‐up using soundscaping with subsequent modal analysis of the actual state. The effectiveness of any changes made can be estimated using simulation techniques. This approach is confirmed by subsequently implementing the selected measures and verifying them by performing the appropriate measurements.

The paper takes care of the increasingly important field of converter‐fed drive systems and their special acoustical challenge. It shows a practical way to reduce audible noise combining measurements and simulations.

Combining the measurement of the acoustic camera with the simulation of modal shapes is a fast way for optimizing an inverter‐fed drive system.

The conventional two-level inverter suffers from harmonics, higher direct current (DC) link voltage requirement, higher dv/dt and heating of the rotor. This study aims to overcome by using a multilevel inverter for brushless DC (BLDC) drive.

This paper presents a comparative analysis of the conventional two-level and three-level multilevel inverter for electric vehicle (EV) application using BLDC drive.

A three-level Active Neutral Point Clamped Multilevel inverter (ANPCMLI) is proposed in this paper which provides DC link voltage control. Simulation studies of the multilevel inverter and BLDC motor is carried out in MATLAB.

The ANPCMLI fed BLDC simulation results shows that there is the significant reduction in the BLDC motor torque ripple, switching stress and harmonic distortion in the BLDC motor fed ANPCMLI compared to the conventional two-level inverter. A prototype of ANPCMLI fed BLDC drive along with field programmable gate array (FPGA) control is built and MATLAB simulation results are verified experimentally.

A new wire arc additive manufacturing (WAAM) process combined with gravity-driven powder feeding was developed to fabricate components of tungsten carbide (WC)-reinforced iron matrix composites. The purpose of this study was to investigate the particle transportation mechanism during deposition and determine the effects of WC particle size on the microstructure and properties of the so-fabricated component.

Thin-walled samples were deposited by the new WAAM using two WC particles of different sizes. A series of in-depth investigations were conducted to reveal the differences in the macro morphology, microstructure, tensile performance and wear properties.

The results showed that inward convection and gravity were the main factors affecting WC transportation in the molten pool. Large WC particles have higher ability than small particles to penetrate into the molten pool and survive severe dissolution. Small WC particles were more likely to be completely dissolved around the top surface, forming a thicker region of reticulate (Fe, W)₆C. Large WC particles can slow down the inward convection more, thereby leading to an increase in width and a decrease in the layer height of the weld bead. The mechanical properties and wear resistance significantly increased owing to reinforcement. Comparatively, samples with large WC particles showed inferior tensile properties owing to their higher susceptibility to cracks.

Fabricating metal matrix composites through the WAAM process is a novel concept that still requires further investigation. Apart from the self-designed gravity-driven powder feeding, the unique aspects of this study also include the revelation of the particle transportation mechanism of WC particles during deposition.