A Customized Systems for Tool Path Generation for Machine Elements

1
A Customized Systems for Tool Path Generation for
Machine Elements

• Names
  ID
• Nawaf Abdullrahim Al Shaheen 200212713
• Nawaf Ahmad Al-Mohaideb 200205606
• Talal Moh. Al-Shehhi 200101574

Advisor Dr. A.M.M. Sharif Ullah
2
Content

• Objective
• Main Tasks
• Gear Geometry Validation
• Selection of manufacturing parameters
• Smart User Interface
• Case Study
• Conclusion

3
objective

• To Develop a Customized System for Computer Aided
  Design and Manufacturing of Machine Elements
  (e.g., gears, cam)

4
Introduction

• Target product
• Competitive
• Reliable
• High Quality
• Method
• Develop a system that is able of cutting the
  involute profile accurately

5
Summary of Previous work
6
Tasks
Geometric Modeling for Manufacturing
Mechanical Assembly
Drawing of the assembly
Spread Sheet based Program
Set Requirements
Program Validation
Obtain mechanical elements
Manufacturing parameters selection
Validation of the mechanical system
Smart Interface
Final Prototype
7
Tasks1 System Validation

• Previous gear geometry
• Run the system

8
Task1 System Validation

• Observation
• The top of the gear-teeth was tipped off
• the fillet of the gear pinion was over cut

9
Task1 System Validation

• Improvements

10
TAsk1 System validation

• System limitations

11
Task2 Manufacturing Parameters

• Increasing the material removal rate MRR
• Safety of the cutting tool
• Safety of the CNC machine
• Manufacture smooth finish

12
Task2 Manufacturing Parameters

• MRR cm3/min
• ap width of cut mm
• ap depth of cut mm
• vf feed velocity mm/min

13
Task2 Manufacturing Parameters

• Pc kW
• ap width of cut mm
• ap depth of cut mm
• vf feed velocity mm/min
• Kc Specific cutting pressure MPa
• ? efficiency of cutting machine

MRR
Material Property
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Task2 Manufacturing Parameters
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Task2 Manufacturing Parameters

• vc m/min
• D cutting tool diameter mm
• N revolution per minute rev/min

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Task2 Manufacturing Parameters

• MRR
• Increase to maximize the profit
• Limitations
• Cutting tool size D
• Spindle speed N
• Affecting the velocity of cut vc
• Increasing the power required
• If Kc MRR

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Task2 Manufacturing Parameters
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Task3 User Interface
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Form selection
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User interface properties
21
User interface properties
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User interface properties
23
Adding group box
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Text box final look
25
User interface design
26
Module
27
Output summary
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Output summary clicked
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Gear and pinion
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Source code

• x-75 , y152

Form 3 Code
Private Sub Form3_MouseMove(ByVal sender As
Object, ByVal e As System.Windows.Forms.MouseEvent
Args) Handles Me.MouseMove Coordinates.Text
"x " e.X - 300 " , y " (-1). (e.Y -
200) End Sub
Module
Public bmp As New Bitmap(600, 400)
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Negative Y value
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Form 3
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Visual basic mouse move code
34
Obtaining the Highlighted values
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Gear construction circles
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Pinion construction circles
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Values show code
Private Sub Form3_Load(ByVal sender As
System.Object, ByVal e As System.EventArgs)
Handles MyBase.Load GearTeeths.Text "
" GearNOTeeths a.DrawString(Math.Abs(CDbl(GearO
utput.Rows(0)("x")) 2).ToString, New Font(New
FontFamily("Tahoma"), 11), Brushes.Red, 70, 200)
a.DrawString(Math.Abs(CDbl(PinionOutput.Ro
ws(0)("x")) 2).ToString, New Font(New
FontFamily("Tahoma"), 11), Brushes.Blue, 520,
200) a.DrawString(Math.Abs(CDbl(GearOutput.Rows(0
)("x")) 2).ToString, New Font(New
FontFamily("Tahoma"), 11), Brushes.Red, 300, 10)
a.DrawString(Math.Abs(CDbl(PinionOutput.Ro
ws(0)("x")) 2).ToString, New Font(New
FontFamily("Tahoma"), 11), Brushes.Blue, CInt(280
DistanceCenterSI), 265) End Sub
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Moving the root circle values
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Drawing gear and pinion
For i As Integer 0 To GearOutput.Rows.Count -
1 GearPoints(i).X
OutputSummary.Rows(i)("GearX") 300 ' note the
increment in x GearPoints(i).Y
OutputSummary.Rows(i)("GearY") - 200 ' note the
negative increment in y y in Windows forms
increases downward! Next
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Axis origin code

• a.DrawLine(New Pen(Color.Black, 2), 300, 0, 300,
  -400)
• a.DrawLine(New Pen(Color.Black, 2), 0, -200, 600,
  -200)

41
Axis origin code

• Coordinates are made of an x and y pair. A line
  segment exists between two coordinates.
• If you don't have two points (4 coordinates) you
  cannot draw a line. One is the "start" point,
  another is the "end" point.

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CNC FILE SAVING
43
.H file process
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.H file process
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.H file process
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.H file process
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.H File Process
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Translation Equations

• X_offset_newx_offset-(Xd(L/2)-a)
• Y_offset_newy_offset-(Yd(W/2)-b)

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.H File Process
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Saving file process
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CNC preview mode
52
Commercial full
53
Commercial trial
54
Commercial trial
55
Expired
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about
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Software requirments
58
Task4 Case Study

• The goal of spur gear.
• The gearbox.
• Consider AutoCAD Program.

59
AutoCAD Program

• Coordinates of x y

H4E4,F4
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AutoCAD program

• Convert from Excel to Notepad file
• Type the _pline
• Type End
• Save with scr

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AutoCAD program

• Write the word script on the command

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AutoCAD program

• The desired workpiece of gear

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AutoCAD program

• Gear box with 4 views.
• Motor with 1360 rpm.
• The power is 0.18 KW.
• length shaft is 40 mm.

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Gear ratio
NA is revolution per minute of gear A NB is
revolution per minute of gear B nA is number of
teeth on A nB is number of teeth on B DA is
diameter of gear A DB is diameter of gear B
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Gear ratio

• Power Torque
• Power KW
• TA is the torque transmitted by A
• TB is the torque transmitted by B

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Results

• Output of speed

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Results

• The Torque on gear A
• Power input(KW)

68
Results

• Output of torque for the gear wheel B

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Results

• Output of power of the gear B
• Power output KW
• Power output KW
• Power output KW 0.18 KW

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System limitations

• Cutting Tools
• ?Variable size.
• Solid carbide.

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System limitations

• Fixture size
• Limit is 170 mm 170mm.
• New idea.
• Fixed in two position.

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Run the Program

• Coordinates X Y.
• Recognize the cutting tool.
• Depth of workpiece.

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Rapid Prototyping

• Another way of production.
• Coordinates XY.
• Represents gear Profile.
• AutoCAD Program.
• STL file.
• Desired workpiece.

74
System configuration

• System configuration
• Develop the local industry by computer aided
  manufacturing.
• In our project we have selected to manufacture a
  spur gear.

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Problems

• System design.
• Remodeling the spur gear.
• Redesign the offset.
• Building a smart interface.
• Manufacturing parameters selection.

76
limitations

• Manufacturing limitations
• Fixture size.
• Cutting tool alignment.
• Workpiece preparation.
• Selection of manufacturing parameters.

77
Results

• Reduce the speed to half.
• Our gear transmitted the power smoothly.
• Provided a smart user interface.
• Present a whole manufacturing system.

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Prototype

• Final stage of our work

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Total Cost

• Cutting tools ... 345 AED
• Blank Material (aluminum) .1020AED
• Mechanical Assembly ..2500 AED
• Accessories ..... 635 AED
• Total ...4500 AED

80
references

• http//dotnetmasters.com/historyofbasic.htm.
• http//www.vbforums.com
• http//www.vbdotnetforums.com
• http//www.cnczone.com/
• http//www.eng-tips.com
• http//forums.microsoft.com/MSDN

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• Thank you for listening ,,All questions are
  welcomed