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Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect ScienceDirect Available online at www.sciencedirect.com Available online at www.sciencedirect.com Procedia Manufacturing 00 (2018) 000–000 Procedia Manufacturing 00 (2018) 000–000 ScienceDirect ScienceDirect www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia Procedia Manufacturing 30 (2019) 677–684 Procedia Manufacturing 00 (2017) 000–000 www.elsevier.com/locate/procedia 14th Global Congress on Manufacturing and Management (GCMM-2018) Virtual reality barrel shaft design and assembly planning accompany with CAM T. Channaronga*, and B. Suthepb aIndustrial Engineering Department, Princess of Naradhiwas University, 99 Khok Kian Muang Narathiwat, Narathiwat 96000, Thailand bProduction Engineering Department, King Mongkut’s University of Technology North Bangkok, 1518 Pracharat 1 Road, Wongsawang Bangsue Bangkok 10800, Thailand Abstract This paper proposes the virtual reality concept to design and assembly planning for a barrel shaft. The shaft model was created on CAM and digital verification for effective functional design together with simulation as traditional method. Presently, virtual reality technology is sophisticated to mechanical components design and assembly animation which can help a design engineer in order to show possibility alternative assembly planning and achieve optimization. Collaborative virtual environment system was used to create the assembly plan animation. © 2019 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the scientific committee of the 14th Global Congress on Manufacturing and Management (GCMM-2018). Keywords: Virtual Reality Design and Assembly Planning, Barrel Shaft, Digital Verification, Optimization, CAM *Corresponding Author E. mail address: channarongtrakunsaranakom@gmail.com 1.Introduction Currently, the virtual reality (VR) technology is used extensively by covers almost all professions [1]. Due to the flexibility of the VR application such as systems provide an enormous potential for enhancing the 3 D visualization linked with interaction device. It includes the open dynamic engine (ODE) and collision detection module [2]. Especially, its application in engineering, medical, military, education and another fields. This introduction aims to present also the context of the research respect to the mechanical parts design for manufacturing industries in Thailand. Because this research expects to build new knowledge for the benefit of Thailand’s economy which relevant to the design process and simulate throughout to manufacturing process. It focuses on the movement simulation of 2351-9789 © 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the scientific committee of the 14th Global Congress on Manufacturing and Management (GCMM-2018). Selection and peer-review under responsibility of the scientific committee of the 14th Global Congress on Manufacturing and Management 2351-9789 © 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) * Paulo Afonso. Tel.: +351 253 510 761; fax: +351 253 604 741 E-mail address: psafonso@dps.uminho.pt (GCMM-2018). 2351-9789 © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the scientific committee of the 14th Global Congress on Manufacturing and Management (GCMM-2018). 10.1016/j.promfg.2019.02.063 2351-9789 © 2019 The Authors. Published by Elsevier Ltd.
678 2 T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684 T. Channarong and B. Suthep / Procedia Manufacturing 00 (2018) 000–000 mechanical components in VR environment [3]. Furthermore, to simulate the tools trajectory for CNC milling and turning machines are performed by 4-5D contouring through computer aided manufacturing (CAM) software [4]. The experimental methods are expected to determine design and simulate tasks through collaborative virtual reality environment system (CVRES). The experiment is used to validate and compare with the performance of CVRES to optimize the design and movement simulation tasks. The different various of CVRES respect to arrangements of the engines/equipment as well as applications. A CVRES consist of several VR modules and the modules must be connected to interaction device to support an expected task.In this context to achieve assess barrel shaft transmissions for motion simulation experiment. The CVRES consist of analysis module and inserted with the preliminary sensors: stopwatch, orientation, and instability sensor. In this research has selected the most appropriate virtual environment for this context using a haptic arm with force-feedback combined with 3D glasses on 2D wall screen [5]. By the time that the design process ends, the next step is analytical process which the most appropriate tools selection and trajectories for CNC milling & turning machines. The main goal is not to compare a few specific environments but to the comparison itself. Incidentally, the complexity of design or global innovative design are challenges for designers and engineers. But the main objective is to offer them a correct design and simulation frameworkas well as the application of the tools technologies to suit the context. Nowadays, the tools used (CAD/CAM/CAE/CNC) for manufacturing industries are widely popular for designer, engineers, and manufacturing experts [6]. Meanwhile, the VR technology in high performance platform but they often do not know which platform or environment will be the most effective for the expected tasks. If our research is successful as expected, we may have use VR technology to develop capabilities design and manufacturing. Particularly, for the manufacturing of mechanical parts in designing activities such as assembly and simulation [7]. 2. Research Methodology The goal of this research was expected to build high level assessment technique to assess motion performance and to compare barrel shaft in different dimensions. We propose a process to measure objective of criteria using basic level measures. The VR session is instrumented with primary sensors that can be reported automatically. This research proposes to achieve VR environment that suits the context of design, assembly and simulation activities. The general structure and procedure of research methodology for this context includes: system and implementation methodology to reach the desired goals which are shown in Fig. 1. The general structure and procedure of research methodology The desired goals System and implementation methodology ManufacturingPreparation Implementation CVRES Senses Tool management Machines Selection User (Hand & Eye) - Generic tools database - Personal tools database -Lathe with live tooling -Vertical mill5 axis Movement Simulation Taskor context System or Software CVE Tools trajectory simulation Physical Environments Environment Database analysis Fig. 1. The general structure and procedure of research methodology
T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684 679 2.1 System and implementation methodology The CVRES module consists of four core components; the user or participant, interacts with computer operating systems, the task or context, is the activity related to the design phase and will be tested in this research for motion tasks, the system or software which is called a Collaborative Virtual Reality Environment System (CVES), the environment, defines the used hardware with various combinations of interaction and visualization which it has defined physical environments: a haptic arm with force-feedback combined with 3D glasses on 2D wall screen as shown in the Fig 2. Fig. 2. A haptic arm interface modeled haption Virtuose 6D35-45 2.2 Manufacturing preparation method This section contains information about the manufacturing process and operations. Manufacturing are processes defined to produce a product or sub-product [8]. The manufacturing process determines the required operational resources, setup time, production time, and cost calculation [9]. In this context, machines and tools are selected to produce virtually a barrel shaft manufacturing process with a good quality, consistently servicing the parts. The manufacturing preparation method for this experiment has been created using the Top Solid v 7.11 program. The main context in this section is the selection of machinery to use for manufacturing process. They are CNC machines; CNC lathe and CNC vertical milling. The CNC lathe machine can perform together with milling operation. It is able to work as milling, drilling, and grinding tasks as shown in the Fig. 3. The 5 axes CNC Vertical mill machine is shown in the Fig 4. Fig. 3.Virtual CNC Lathe machine
4 T. Channarong and B. Suthep / Procedia Manufacturing 00 (2018) 000–000 680 T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684 Fig. 4. CNC 5-axis milling machine 2.System overview System overview for the general purpose of 3D visualization and interaction devices manipulation. The CVRES consists of several modules but for this context selected the following ones: a communication server, a configuration editor, a 3D viewer enabling virtual reality usage, an analysis module, and haptic connector. The server dispatches events between the various modules. Moreover, CVRES is a multi-agent-based system dedicated to collaborating within a virtual/augmented environment. A socket-based communication system is employed to ensure the communication between agents. Every agent oversees a behavior of the global virtual environment. The various CVRES modules used in our experiment. In the current experiment, the expected sub-behaviors correspond to five modules; CVRES-Editor module The CVRES-Editor module enables to import and to export the object format. Moreover, in this module we can modify the scene (colors) and provide access to any state value of the scene. “It is necessary to import” a STL or OBJ file format into CVRES Editor before working with the collaboration virtual reality environment software. CVRES-Viewer module CVRES-Viewer oversees creating the 3D visualization and sending it to the final display which can be holographic, stereoscopic or a simple 2D screen. CVRES Viewer opens 3D windows which can display diverse imported 3D objects by “wavefront OBJect” file format, it is simply referred to as the (OBJ) file format. Concerning the 3D models imported for this research, all elements were imported and exported in OBJ data formats by using CAD software. The OBJ file format can be imported directly into CVRES Viewer module which generates the scene and 3D models. CVRES-ODE module The CVRES-ODE module is especially important for simulating dynamics articulated rigid body, which will be the invisible model for collision detection and force-feedback. It is particularly good for simulating moving objects in changeable virtual reality environments because it is quite fast, robust, and stable. Collision detection prevents part interpenetration for the user regarding how to move position and orientation of the parts to finish the operation. CVRES-Happy module CVRES-Happy is a module to take in charge the connection with a haptic arm. It can survey the position of the human operator’s hand and it drives the arm actuators to apply a force feed-back, if feedback is activated [10] during
T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684 681 virtual assembly and simulate tasks. The haptic arm available in our laboratory, is the Virtuose 6D35-45 which is composed of two main articulated segments fixed on a rotating base. CVRES-Analysis module CVRES-Analysis module has several basic sensors which can be selected and adjusted from the CVRES-editor. This research selected two basic sensors to evaluate the way users performing the movement simulation tasks during our experiment. These sensors are the duration and instability sensors. The duration sensor measures the duration of the experiments. The duration is the interval of time between the event launching the analysis and the event stopped the analysis. No special attributes are expected to define this sensor since it is a global sensor associated with the whole analysis. The instability sensor intends to measure the evolution of a position during a lap of time. Instability sensor evaluates the gesture instability. The position of two points in a frame defined by a transformation matrix defining the position of the manipulated object is continuously analyzed. The trajectory of these points is linearized by small intervals of time and the sensor compares the real path length of the point respecting to the linearized trajectory interval per interval. The ratio gives an idea of the oscillation of the trajectory around a more efficient straight path. It depicts the gesture shivers. This ratio is recorded by the analysis module for every conducted experiment. A task can be defined, processed and repeated several times as a record file provides the raw result of these basic sensors. 3. CAD for VR environment preparation Nowadays, 3D geometric models is created using CAD software by relying on the expertise of designers, engineers, and manufacturing experts. In general, CAD software is efficient in import and export in various file formats such as Stereo Lithography (STL), Standard for Exchange of Product model data (STEP AP203), Virtual Reality Modeling Language (VRML), and so on [10-12]. In this research, the 3D models are individually exported into STL file formats and transformed into CVRES-Editor module. For this reason, the translation mode is a 3D model of the VR environment is thus, once the initial process for working on CVRES-Viewer module. Furthermore, to reopen the STL file merge nodes and to export the meshes into OBJ files format. Besides, choosing to use OBJ file format because it can compress the file well and an intermediary step is performed through the STL to OBJ conversion. Particularly, a barrel shaft mechanism movement simulation able to interact with the CVRES-ODE module. For this research, the kinematics constraints of barrel shaft was rebuilt from scratch directly of the CVRES-ODE module. The operation will be more complete when it was linked to CVRES-Happy module because it’s a user interface or dashboard that connects a person to a machine, system, or device. In addition, the CVRES-Analysis module must be linked to the main CVRES as well because it’s a module to record experimental data and analysis. The case study for this experiment as shown in Fig.5. Critical position Barrel shaft Fig. 5. A case study on power transmission of shaft cam
682 T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684 4. Experiment protocol As already discussed, finding appropriate dimensions by virtual rotating simulation on the barrel shaft are selected for the experiment protocol since motion simulation activity involved a lot of interaction and real time. It is decided to limit the experimentation elementary task to give it through a critical position of a barrel shaft. The experiment is tested by 10 participant users. Every participant is expected to repeat the task 10 times which means a barrel shaft is moved forward and reward rotated 10 times by using a haptic arm. Therefore, the participants repeats 110 times within the physical environment of the haptic arm with force-feedback combined with 3D glasses on 2D wall screen. The barrel shaft was rotated about 2 seconds per each time on the physical environment configuration by using a haptic arm as shown in Fig 6. Fig. 6.Rotation direction for experiment protocol Forward direction Reward direction the barrel shaft design. The user is supported to analyze the possibility for the barrel shaft to rotate continuously without blocking or having other unwanted behavior. Simultaneously, the balance and stability of manipulation is evaluated in the experiment by using of basic sensors of the CVRES. Factors affecting the expected movement for a barrel shaft are the dimension of internal and external arc radius as well as the distance between the two arcs. Therefore, the distance between internal and external are related to the two arcs independently issued from the CAD fillet command. For the experiment considered the dimension of a barrel shaft through 11 types of radius values defining the distance between both arcs and the result of the most accurate dimension will be simulated the tools trajectory in the next step. The various dimensions that affect for a barrel cam rotation as shown in Table 1. Table 1. The various dimensions that affect for a barrel cam rotation 11 20.00 ± 0.021 This experiment context aims to analyze and find the appropriate dimension of internal and external arc radius for The main dimensions Type Internal arc (Radius) Width of slot External arc (Radius) 10.00± 0.021 11.00 ± 0.021 12.00 ± 0.021 13.00 ± 0.021 14.00 ± 0.021 15.00 ± 0.021 16.00 ± 0.021 17.00 ± 0.021 18.00 ± 0.021 19.00 ± 0.021 1 2 3 4 5 6 7 8 9 10 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 30.00 ± 0.021 31.00 ± 0.021 32.00 ± 0.021 33.00 ± 0.021 34.00 ± 0.021 35.00 ± 0.021 36.00 ± 0.021 37.00± 0.021 38.00 ± 0.021 39.00 ± 0.021 40.00 ± 0.021 Internal arc External arc Width of slot
T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684 683 5. Manufacturing preparation and tools management. A barrel shaft type 6 was selected for manufacturing preparation and it was imported into CAM software to simulate the tool trajectory. In this case, focused on the use of 5 axis CNC lathe and milling machines because it is popular in the industries for parts manufacturing. The CNC vertical mill 5 axis and lathe with live tooling machines were selected to experiment protocol through the stock to leave 0.0 mm, axial depth 0.5 mm, and groove depth 10 mm for this experiment. The geometrical characteristics of the cutting part for each tool consists of cutting length 35 mm, number of tool teeth 4 teeth’s, and cutting tool material was coated carbide. The manufacturing preparation for this research, is 4 x radial roughing machining by groove machining of the barrel shaft only because it’s apposition that requires high accuracy of dimensioning and tolerancing. The tool trajectory simulation on CAM software, each machine and tool has been replicated repeatedly for 10 times by 10 participants. Participants performed with caution and precision control throughout the experiment.The variables that must be controlled precisely for the experiment include: kind of machining, cutting speed, speed frequency, feed rate, and tool feed rate. Moreover, the key issues to consider for manufacturing preparation process are speed and precision by proceeding under the conditions in Table 2. In this context, it’s 3 D model preparation to perform for manufacturing process associated with machine selection Table 2. The cutting condition of CNC vertical mill 5 axis and lathe with live tooling machines Side mills Tooth feed rate(fz) Index Kind of machining Cutting speed Frequency Feed rate (vf) Tool feed rate (fz x Z) 100 m/min. Ø 14 mm Ø 16mm 2 mm/rev. 4,547 mm/min. 4 x Radial roughing 2,274 rpm 0.5 mm/tooth 1 2 mm/rev. 0.5 mm/tooth 3,979 mm/min. 2 4 x Radial roughing 1,989 rpm 100 m/min. 3,537 mm/min. 2 mm/rev. 4 x Radial roughing 0.5 mm/tooth 3 1,768 rpm 100 m/min. Ø 18 mm 6. Experimental results The experimental results are about the tool trajectory simulation by using CNC vertical mill 5 axis and lathe with live tooling machines were reported the average values of each machine and tool. The experimental resultsare all the same execution timesuch as total time, approach, and machining times.The results summarized of the experiment were presented in Table 3. Table 3. The average values of the tool trajectory simulation for CNC vertical mill 5 axis and lathe with live tooling machines Total time: 05Minutes 27Seconds 04Minutes 17Seconds 05Minutes 35Seconds Work: 05Minutes 23Seconds 04Minutes 13Seconds 05Minutes 20Seconds Rapid: 00Minutes 03Seconds 00Minutes 03Seconds 00Minutes 15Seconds Approach: 00Minutes 01Seconds 00Minutes 01Seconds 00Minutes 01Seconds Machining: 05Minutes 24Seconds 04Minutes 14Seconds 05Minutes 25Seconds Work: 05Minutes 23Seconds 04Minutes 13Seconds 05Minutes 20Seconds Rapid: 00Minutes 01Seconds 00Minutes 01Seconds 00Minutes 05Seconds Retract: 00Minutes 00Seconds 00Minutes 00Seconds 00Minutes 00Seconds 7. Conclusion Virtual reality barrel shaft design and assembly planning accompany with CAM has been presented tool trajectory simulation of CNC machines are experimented with VR method. This method can help a design engineer to understand functionality of the part assembly conception clearly. Furthermore, the machine operator can learn and understand the bill of material accurately and precisely.
684 T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684 Acknowledgement I would like to thank the Princess of Naradhiwas University and Office of the Higher Education Commission, Thai Ministry of Education for granting me a scholarship and providing me with the facilities to complete this research. References [1] Jocelyn Parong and Richard E. Mayer, Learning Science in Immersive Virtual Reality, Journal of Educational Psychology, (2018) 1-13. [2] Dhalmahapatra K., Das S., Kalbande S., and Maiti J., Virtual Prototype based Simulator for EOT Crane, Industrial Safety Management, (2017) 11-26. [3] Colin R. Smith et al., Efficient Computation of Cartilage Contact Pressures within Dynamic Simulations of Movement, Computer Methods in Biomechanics and Biomedical Engineering: Imaging & Visualization, (2018) 491-498. [4] Jixiang Yang et al., Kinematics Model and Trajectory Interpolation Algorithm for CNC Turning of Non-circular Profiles, Precision Engineer, (2018) 212-221. [5] Xiaojun Chen, Pengjie Sun, and Denghong Liao, A Patient-specific Haptic Drilling Simulator based on Virtual Reality for Dental Implant Surgery, International Journal of Computer Assisted Radiology and Surgery. (2018) 1861-1870. [6] Delvin Grant and BenjaminYeo, A Global Perspective on Tech Investment, Financing, and ICT on Manufacturing and Service Industry Performance, International Journal of Information Management, (2018) 130-145. [7] Andrey Kutin et al., Simulation Modeling of Assembly Processes in Digital Manufacturing, Procedia CIRP, (2018) 470-475. [8] Justyna Trojanowska et al., A Methodology of Improvement of Manufacturing Productivity Through Increasing Operational Efficiency of the Production Process, Advances Manufacturing, (2017) 23-32. [9] Xingyu Li et al., Real-Time Teaming of Multiple Reconfigurable Manufacturing Systems, CIRP Annals. (2018) 437-440. [10] Shuo-Fang Liu et al., A Study of Perception Using Mobile Device for Multi-haptic Feedback, Human Interface and the Management of Information, (2018) 218-226. [11] Jakub Wojciechowski and Olaf Ciszak, Spatial Adjusting of the Industrial Robot Program with Matrix Codes, Advances Manufacturing, (2017) 521-531. [12] Lingyan Peng BDS et al., Accuracy and Reproducibility of Virtual Edentulous Casts Created by Laboratory Impression Scan Protocols, The Journal of Prosthetic Dentistry, (2018) 389-395.
