ANNALS OF MTeM FOR 2011 &

OF THE 10TH INTERNATIONAL CONFERENCE MODERN TECHNOLOGIES IN MANUFACTURING 6th-8th OCTOBER 2011

PROCEEDINGS

EDITOR: CS. GYENGE

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Annals of MTeM for 2011 & Proceedings of the 10th International MTeM Conference Published by MTeM 2011, Cluj-Napoca, Romania, Editor Cs. Gyenge

EDITOR'S NOTE This Publication was reproduced by the photo process, using the manuscripts and soft copies supplied by their authors. The layout, the figures and tables of some papers did not conform exactly with the standard requirements. In some cases the layout of the manuscript was rebuilt. All mistakes in manuscripts there could not been changed, nor could the English be checked completely. The readers are therefore asked to excuse any deficiencies in this publication which may have arisen from the above causes. The editor and the MTeM Cluj Napoca are not responsible either for the statements made or for the opinion expressed in this publication. Copyright 2011 by MTeM CLUJ-NAPOCA Abstracting and nonprofit use of the material is permitted with credit to the source. Libraries are permitted to photocopy for private use of patrons. Instructors are permitted to photocopy isolated articles for noncommercial classroom use without fee. After this work has been published by MTeM Cluj-Napoca, the authors have the right to republish it, in whole or part, in any publication of which they are an author or editor, and to make personal use of the work. Any republication, referencing, or personal use of the work must explicitly identify prior publication in the MTeM Cluj-Napoca of the 10th International Conference Modern Technologies in Manufacturing, Editor Cs. Gyenge.

Descrierea CIP a Bibliotecii Nationale a Romaniei INTERNATIONAL CONFERENCE MTeM Proceeding of the 10th International Conference MTeM, Cluj-Napoca, 6th - 8th October 2011 Ed:Cs.Gyenge Cluj Napoca: p. 335; cm 21/29,7 Bibliogr. Index. ISBN 978-606-8372-02-0 Editura Mure Tiparul executat la S.C. CROMATIC TIPO S.R.L. Targu Mures, str. Calarasilor nr. 58 Tel./fax: 0265-215597 E-mail: cromatictipo@cromatictipo.ro Web site: www.cromatictipo.ro Additional copies can be obtained from the publisher: MTeM CLUJ-NAPOCA, TECHNICAL UNIVERSITY OF CLUJ-NAPOCA DEPARTAMENT OF MANUFACTURING ENGINEERING, B-dul Muncii 103 105, 3400 CLUJ-NAPOCA, ROMANIA PHONE:0040 64 415051 FAX: 0040 64 415054 E-MAIL: cgyenge@tcml.east.utcluj.ro

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CONTENTS PLENARY SECTION KEY NOTE PAPERS A

Albu, S., Pozdrca, Al. The contact between a face milling cutter and a helical surfaces Andras, I., Kovacs, I., Andras, A., Tomu, B. Computer aided simulation of coal extraction process with complex technological systems

1 5

B
Bala, M., Blc, N., Pcurar, R. Research regarding heat affected zone after edm-wc process Bil, D. Selection criteria for cutting plates at high speed machining Bere P., Berce P., Iancau H., Sabau E. Research regarding the delamination of carbon/epoxi composites plates Bichi, I., Banabic, D., Coma, D.S. Research on the shock heat treatment method used for modifying the formability of aluminium alloys Bir, V., Banabic, D. Advanced non-real-time monitoring systems: two case studies Bob, M., Bob, D. Aspects regarding profile modification of spur gears Bocan, I., Hancu, L., Borzan, M., Fabre, M., Ivens, I. Mechanical behavior of plain woven carbon fabric reinforced shape memory polymer composites Bodzs, S., Duds, I. Modeling and mathematical analysis of conical helical surface Bondrea, I., Petruse, R. Augmented reality applied in assembly design Borzan, M., Trif, A., Bereschi, A. Studies about screw tap execution technology and screw tap control Brdlk, P. The batching injection of co2 in blow molding process Bucur, B., Bolo, V. experimental study of the thermal limit for the gearbox worm facegear with reverse tapered pinion

9 13 17 21 25 29 33 37 41 45 49 53

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Capustiac, A., Banabic, D. An application of virtual reality in the automotive industry
Chean, P., Bolo, V. The influence of the tool path regarding the roughness resulted from the milling process of the complex surfaces Cigan V., Vucan I. Researches regarding the behavior of a al2o3 particle in a plasma jet considering the injection angle and the diameter of the particle Cioban, D., Achima, Gh., Popa, A., Budai, A. F. Aspects of public service management Ciotea, M., Bolo, V. Numerical modeling research on the double front worm wheel

57 61 65 69 73

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Costea, A., Gyenge, Cs. Research on the predictive maintenance procedure for paper industry uboov,N., Kuric,I. Software program for training of control system sinumerik 840d Curta, R.T., Blc,N., Crean, A. New software to generate the CNC code for turning operations

77 81 85

D
Dezs, G., Szigeti F., Varga Gy. Study on the process of environmentally conscious drilling Drstvenek, I., Valentan, B., Bali, J., Brajlih, T. Speed evaluation and comparisson of additive manufacturing systems Duds, L. Introducing improved space analysis capabilities of surface constructor Duds, I. General mathematical model for investigation of cylindrical and conical worms and hobs

91 95 99 103

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Farkas, F. A., Bode, F., Vuscan, I. Contribution for controll of autonomous underwater vehicle (auv) Farkas, F. A., Bode, F., Vuscan, I. Numerical simulation analysis and form optimization of autonomous underwater vehicle Filip, F.C. Methods of implementing continuous flow Florea, C., Iancu, H. Considerations regarding the influence of manufacturing processes of the composite structures on their mechanical behaviour Fodorean, I., Berce, P., Muresan S., Pop, D. Injection moulding using metal spraying technology Fulop, D., Gyenge,Cs., Fulop, I. Risk assessment method regarding to environmental impact and safety and health of workers in pulp and paper industry

107 111 115 119 123 127

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Grozav, S., Oprea O. V. Gligor, Gh. Cam system for design and simulation process of extrusion for small pieces used in mining industry Gyenge, Cs., Murariu, V. Improuvements to the sonic drilling head

131 137 141 145

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Hamidi, B. Optimization of the hoisting system of vehicle J Julean, D., Nedezki, C. Assesment of factors influencing surface roughness on turning of aa6060-t6

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Kiksi, V., Achima, G., Harag, S., Budai, A. F. Lubrication of injection molds used for the pressurized aluminum casting Kodcsy, J., Lska, J., Danyi, J. Magnetic finishing of metal parts based on plastic

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deformation and abrasion Kolev, I., Sovilj, B., Sovilj-Niki, I. Mathematical model for optimization of the cutting conditions by drilling Kostal, P., Mudrikova, A. Laboratory of flexible manufacturing Krajov, K., Pechek, F. Design of material flow, machine and devices layout and their application on the model example Krrabaj, S., Bytyci, B., Osmani, H. Generating of technological parameters for the design and optimization blanking tools Kuric, I. Selective and dynamic classification

155 159 162 166 170 174 178 182 186

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Lavrynenko S. N., Mamalis A.G., Rucki M. instrumental providing of ultraprecision mashining of polymers for bioengineering destination Legutko, S., Wieczorowski, K., Kluk, P. research of the state of surface layer after centerless grinding Leordean, D., Marcu, T., Prem, F., Radu, S.A., Berce, P. Researches regarding manufacturing of porous metal structures for medical application produced by selective laser melting (SLM) Luca, A., Balc, N., Drstvensek, I., Popan, A. Mathematical modeling of aluminum vacuum casting process

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Micaciu. A., Vucan, I. Device for grinding of recees helicoidal surfaces at the cutting tools adaptable on the plane grinding machines Micaciu A., Vucan I. Establishing the formula for adjusting a device for checking the pitch of the exterior cylindrical helical surfaces Mihailesc, N., Achima, Gh., Popa, A., Sudrijan, M., Budai, A. F. Possibilities of increasing the quality of sheet metal parts using the fine blanking Mircea, A., Vuscan I., Considerations about the kinematics motions of the machining centers using specific devices Murean, S., Blc , N., Pop , D., Fodorean , I. Influence of process parameters to manufacture titanium parts by SLM Murean, C., Achima, Gh., Popa, A., Budai, A. F. Technological aspects regarding the bending of large diameter tubes

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Nieszporek, T., Boca, V. A new method of manufacturing the worm gear with concave profile

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Olh, L. M., Gyenge, Cs., Bogr, I. New technological solution for gear transmission manufacturing Ommik, M., Barnek, I. The machine part control by using on - machine measurement systems

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Annals of MTeM for 2011 & Proceedings of the 10th International MTeM Conference Published by MTeM 2011, Cluj-Napoca, Romania, Editor Cs. Gyenge

Osmanaj, S., Selimaj, R. Analysis of voltage source inverter through d, q model Paclt, R. Runner system of plastic injection mould Pcurar, R.A., Berce, P., Mller, P., Bala, M. The manufacturing of silicone rubber molds for the food industry Patalita, C.P., Vucan, Gh. I. Intelligent systems for machining processes monitoring Pescaru, R., Oancea, Gh. Parametrization of curves obtained from clouds of points using catia environment Petera, P. Construction of the mold for observation the filling stage of pim technology in automatic cycle Pokordi, L. Stochastic model of manufacturing equipments maintenance processes Pop, D., Berce, P., Filip, A., Muresan, S., Fodorean, I. Experimental research in the field of SLM, for the production of biocompatible components Pop, G. M., Popa, M. S., Pfeifroth, T., Koukach, D. Mathematical modeling and analysis of process temperatures in drilling reinforced composites using response surface methodology Pop, G. M., Popa, M. S., Contiu, G., Koukach, D. Process temperature determination in drilling reinforced plastics composites using ir thermography Popan, A., Blc, N., Luca A., Curta, R. A new software solution for abrasive water jet cutting Popescu, A., Iancu, H., Hancu, L., Prun, R. Research on extrusion optimization for reinforced polyamide Portik, T., Varga, T., Pokordi, L. Development of supplier-rating based on fuzzy set theory Prem, F., Leordean, D., Balc, N., Pacurar, R. The influence of working parameters of SLM technology on surface quality and precision of stainless steel parts

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Silvia, ., Nina, D., Karol, V. Distinction of the individual components before assembly in the workspace of intelligent assembly cell Selimaj, R., Osmanaj, S. Inside air temperature and modeling of closed space by nonstationary heat transfer conditions Simon, V. Manufacture of face-hobed spiral bevel gears on CNC hypoid generator Stoica, L., Achima, Gh., Popa, A., Budai, A. F. The quality of small diameter tubular parts obtained by cold extrusion

287 291 295 299

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Tirla, A., Popa, M. S., Koukash, D., Preja, D., Badiu, I. Mathematical modelling of the EDM process using the Cu-St pair of materials. Tirla, A., Popa, M. S., Preja, D., Koukash, D., Simon, V. Mathematical modelling of the edm process using the graphite-steel pair of materials.

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Trif, A., Borzan, M., Barboni, E. Contributions about the optimisation of the guillotine knives geometry used in the company "s.c. novis house publishing and printing s.r.l." ClujNapoca Trohk, A., Kolozsi-Tth, M. The research of wireless industrial communication systems for mechatronic and logistics systems

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Velchev, S., Kolev, I., Sovilj, B., Ivanov, K., Sovilj, N. Method of defining the tools effective rake angle in case of small thickness of the cutting layer Vucan, Gh. I., Patalita, C.P. Early detection of machine faults based on vibrations monitoring and analysis

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INTELLIGENT SYSTEMS FOR MACHINING PROCESSES MONITORING

PATALITA, C.-P.; carol.patalita@tcm.utcluj.ro gheorghe.vuscan@tcm.utcluj.ro VUCAN, Gh. I.;
Abstract: A manufacturing process, unattended by a human operator, is possible only if a system for monitoring the tool wear state and for tool breakage detection is implemented. To develop such a monitoring system, the paper presents various sensor systems used and a general methodology to build an intelligent system for monitoring machining processes. Key words: Machining monitoring; Tool Condition Monitoring; Artificial Intelligence.

1. INTRODUCTION The key element of an automated machining process is the monitoring and control of the machining process to ensure the required quality: dimensional and geometric precision, surface quality. In general, the machining monitoring systems focuses on tool wear state monitoring, also known as Tool Condition Monitoring (TCM) system. Tool wear is an important factor affecting the dimensional and geometric accuracy, the processed surface roughness and the required energy for machining. 2. DIAGNOSTIC METHODS There are two types of diagnostic methods of cutting tool wear: a. Direct methods: tool wear is measured directly by ultrasonic sensors, laser devices or vision systems; provides high accuracy but is expensive and difficult to implement in the industry; do not provide on-line (real time) monitoring, requiring the interruption of the machining process for carrying out measurements. b. Indirect methods: during machining, are measured other physical quantities, which are influenced by the cutting tool wear: cutting force, mechanical vibration, acoustic emission, temperature in the cutting area, current/power consumption of the drives. Basically, four types of sensors are used extensively in TCM systems: dynamometers, accelerometers, acoustic emission sensors and current sensors. 2.1. Dynamometers Cutting force best describes the cutting process. Information extracted from the pattern of cutting force can be used to predict the quality and accuracy of processed surface profile and to

evaluate the tool wear. As tool cutting edge loses its cutting ability, the cutting force increase due to increasing of the friction between tool and machined part. However, the increasing of the cutting force due to tool wear is strongly dependent on other factors such as type of wear (flank or crater wear), type of material processed and cutting tool material. If the dominant tool wear is flank wear, the increase of the feed force, is higher than if the dominant wear form is the crater wear [Jemielniak & al., 1998]. In turning feed and radial forces describe better the wear state of tool than the cutting force [Liang & al., 2004]. On the other hand, a partial breakage of the cutting edges can lead to an instant increase followed by a decrease of the cutting force, even below normal recorded. However, the high cost of dynamometers, especially multi-axis versions, their intrusive nature in machining process and their lack of overload protection in case of collision make it very difficult to apply them in industry. 2.2. Accelerometers Vibration monitoring is mainly applied to predict the roughness of the machined surface, especially in turning processes. In milling operations, the vibrations are less correlated with surface roughness due to the discontinuous nature of the cutting process. In turning, although the strongest vibration signal is measured in the feed direction, the vibrations in the cutting speed direction are most significant for the machined surface roughness. Vibration monitoring is also applied to diagnose the state of tool wear because the amplitude of vibration increase with the increasing of the tool flank wear. In [Dimla, 2004], a correlation between the vibration signal features and the cutting tool wear was identified. Although vibration sensors have been successfully applied to monitor

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machining processes, there are some practical problems that make difficult their wide application: the cutting speed must be maintained in a relatively narrow range; the amplitude of the signal decreases with the increase of distance between the accelerometer and the cutting edge; mounting the sensor too close to the edge of the tool result in a noisy signal; chips can hit the accelerometer, providing false information or may even damage it. 2.3. Acoustic emission sensors Acoustic Emission (AE) is the energy released in the form of mechanical vibration from a material (work piece, tool, machine body) as it undergoes stress. Such stress may be generated by chip deformation and fracture, friction between chip, tool and work piece, tool breakage, etc. (Fig. 1a). main advantage of AE is that the frequency range of AE signals is much higher than the frequency of machine vibration or environmental noises. Also, AE sensors have no intrusive character in the processing. AE signal analysis has been used successfully in tool wear diagnosis and tool breakage. Although some researchers recommend the use of AE sensors to diagnose the tool wear, other researchers argue that their use as an indicator of wear is inappropriate, because they are more sensitive to noise and variation of cutting parameters and can be used only as secondary sensors, to increase reliability of the monitoring. 2.4. Current and power sensors Current consumption of DC motors used in the cutting process is an indirect measure of cutting force. Current sensors have a high nonlinearity and low operating bandwidth due to rotor inertia that acts as a low-pass filter. Therefore, the current sensors are used only in the slow processes or when rapid response is not essential. Similarly, for AC motors are measured power consumption, which is proportional to the torque supplied, respectively with the cutting force [Abellan-Nebot & Subirn, 2010]. 2.5. Other sensors To monitor machining processes may also be used temperature sensors, optical sensors or ultrasonic sensors. Temperature sensors used in machining are thermocouples, thermal resistant elements, semiconductor elements. The measurement of the temperature in the cutting zone can be a good indicator of the cutting process since the temperature varies as the tool wears due to changes in the tool geometry and its ability to cut. Furthermore, cutting temperature influences chip formation and the generation of surface roughness and accelerates tool wear. However, accurate cutting temperature monitoring is rather complicated, and it is usually monitored by average temperatures around the cutting tool with an important loss of information. The ultrasonic and optical sensors are used especially for monitoring the roughness of the machined surface, but the application of these techniques in industrial environment present some limitations due to heavy operating conditions.. 2.6. Sensors Fusion Using a single type of sensor for monitoring the cutting process has been applied extensively, with more or less successfully, in particular cases defined by specific machining parameters

Fig. 1. AE sources and AE signals [Li, 2002] AE derived from metal cutting consists of continuous and transient signals (Fig. 1b). Continuous signals are associated with shearing in the primary zone and wear on the tool face and flank, while burst or transient signals result from either tool fracture or chip breakage (Fig. 1c) [Li, 2002]. The frequency spectrum of AE typically spans the 10kHz10MHz range. The

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or certain materials processed. In order to increase the reliability of sensor information under varying conditions and to avoid uncertainty, it is useful to use several sensor signals instead of just one single sensor signal. Sensor fusion refers to the use of more than one sensor signal in a complementary manner to provide a more robust prediction of one or more machining attributes [Guo et al., 2008]. Astfel un sistem cu mai muli senzori necomplementari definete un sistem de msur multi-senzor, i nu un sistem cu fuziune de senzori. Therefore, multiple sensors with non-complementary measurements define multi-sensor monitoring system but not a sensor fusion system, and several features extracted from a single signal are not considered to be multi-sensing or sensor fusion. The success of sensor fusion depends on which types of signals are good candidates for a given machining outcome and which extracted features and in which way they must be complemented. For example, using a dynamometer and a current sensor cannot be considered a sensor fusion system since a current sensor provides the same information as the dynamometer but with less accuracy. Cutting forces and vibration measurements are also closely related, and they may not be adequate for sensor fusion, whereas cutting forces and AE are less correlated and can be used effectively as complementary information. Sensor fusion systems require algorithms to combine and fuse the sensor information. In general, two main approaches are usually applied for sensor fusion: statistical approach and artificial intelligence (AI) techniques approach. Statistical approaches relate sensor data to machining process variables through multi-variable regressions, thus defining a statistical process model. AI approaches use complex non-linear models such as neural networks (NN) or Bayesian networks (BN) to relate sensor data to machining process variables, thus defining an AI process model [Abellan-Nebot & Subirn, 2010]. Sensors fusion based on AI technique was successfully applied for tool wear diagnosis, surface roughness prediction and prediction of dimensional accuracy of the machined parts. 3. METODOLOGIE GENERIC PENTRU DEZVOLTAREA UNUI SISTEM INTELIGENT DE MONITORIZARE In Error! Reference source not found. a five steps generic methodology to develop an intelligent monitoring system for machining processes is presented:

Fig. 2. Generic methodology to develop an intelligent monitoring system for machining 1. Sensors selection: the reliability of each sensor, the cost, its intrusive nature and its application mode in the process are taking into account, in order to select the most appropriate sensor system for a given monitoring purpose. 2. Signal acquisition and processing: the selection of hardware equipment for signal conditioning and transmission: signal amplifiers, analogical filters (low-pass, band-pass, or high-pass filters); the selection of the data acquisition system; to avoid aliasing, sample frequency limitation of the acquisition system must be taken into account; if necessary, a digital signal filtering or a signal segmentation is applied to keep only the useful information for target. 3. Feature generation: the sensor signal has to be transformed into features that could describe the signal adequately; Many different features from the time domain, frequency domain and

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wavelet domain can be used for this purpose.; will be generated features from the time domain (peak, peak to peak, average, RMS, variance), from the frequency domain (single harmonics from Fast Fourier Transform, harmonic ratio, kurtosis) or from the wavelet domain. 4. The model of the machining monitoring system is built in several steps: a. Feature selection/extraction: in order to develop robust and reliable models for monitoring, the most meaningful features, which best describe the machining process, are selected (feature selection) or the generated features are combined under certain algorithm to obtain a smaller set of features that have a greater significance (feature extraction). The main techniques used for feature selection are feature ranking and subset selection. The main technique used for feature extraction is Principal Component Analysis (PCA). b. Design of experiments (DoE): establishing the number of steps and procedures that must be met to achieve the desired accuracy of the model; experimental runs in machining for modelling purposes are both economically costly and time-consuming, so an effective design of experiments is mandatory to enable monitoring systems to be applied in industry. In general, four methodologies are applied in DoE: full factorial design, fractional factorial designs, Taguchis orthogonal arrays and response surface design. c. AI technique selection: machining monitoring systems require reliable models which are able to learn complex non-linear relation-ships between process performance variables and process variables in machining; The selection is based on the number of experimental samples, the stochastic nature of the process, the desired model accuracy, the explicit or implicit nature of the model and the previous knowledge of the process. Most applied techniques in machining monitoring are Artificial Neural Networks (ANN), Fuzzy Logic Systems (FLS). d. Model validation is based on experiments. Due to changes in machining operations, the machining model learnt by AI techniques should be periodically verified in order to detect changes in the machining performance. 5. Model processing and extraction of the desired information: system diagnosis predictions on the behaviour and prognosis. 4. CONCLUSION Due to the complexity of the machining process and to the measurement uncertainty, artificial intelligence techniques are preferred to build a reliable monitoring system. The paper gave a review of sensors used in machining monitoring systems and proposed a general methodology for building an intelligent machining monitoring system, reliable and robust. 5. ACKNOWLEDGMENT This paper was supported by the project "Improvement of the doctoral studies quality in engineering science for development of the knowledge based society-QDOC contract no. POSDRU/107/1.5/S/78534, project co-funded by the European Social Fund through the Sectorial Operational Program Human Resources 20072013. 6. REFERENCES

Abellan-Nebot, J.V.; Subirn, F.R. (2010) A Review of Machining Monitoring Systems Based on Artificial Intelligence Process Models. Int. J. Adv. Manuf. Technol., Vol. 47, No. 14, DOI: 10.1007/s00170-0092191-8 Dimla, D.E. (2004) The Impact of Cutting Conditions on Cutting Forces and Vibration Signals in Turning with Plane Face Geometry Inserts. J. Mater. Process. Technol., Vol. 155156, DOI: 10.1016/j.jmatprotec.2004.04.148 Guo, L.; Zhang, J.-F.; Qi, Y.; Wei, Z. (2008) Study on Tool Wear Monitoring Based on Multi-source Information Fusion. In: Advanced Intelligent Computing Theories and Applications with Aspects of Artificial Intelligence; Huang, D.-S. et al. (Eds.), pp 107-114, Springer-Verlag, ISBN: 3540859837, Berlin Jemielniak, K.; Kwiatkowski, L.; Wrzosek, P. (1998) Diagnosis of Tool Wear Based on Cutting Forces and Acoustic Emission Measures as Inputs to a Neural Network. J. Intell. Manuf., Vol. 9, No. 5, DOI: 10.1023/A:1008896516869 Li X. (2002) A Brief Review: Acoustic Emission Method for Tool Wear Monitoring During Turning. Int. J. Mach. Tools Manuf., Vol. 42, No. 2, DOI: 10.1016/S08906955(01)00108-0 Liang, S.Y.; Hecker, R.L.; Landers, R.G. (2004) Machining Process Monitoring and Control: The State-of-the-Art. J. Manuf. Sci.

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