Proposal presented by Mohamed Essid for a New tool path (ISET

Sfax- Tunisia)

WHY

Until now, CAM software has remained less technically developed compared
to computer numerical control: the methodology for calculating the tool/part path or
for simulation is still classic.

The tool path calculation algorithms and the kinematics simulation of the CNC
machines do not take into account the effect of the environmental elements of the high-
speed machining process: the kinematic and dynamic capacities of the machine axis,
the variation of the axis inertia and the numerical capacities of CNC unit (mode of the
feed forward, capacity of the feed forward, Lookahead, the mode and the parameter
of local or global smoothing, the laws of the axes motion: jerk controlled or
acceleration controlled or snap,…).

The reliability of traditional methods for identifying the tool/part path and for
simulating the behavior of the machine in the case of the complex shapes machining
is low. This, limits the use of the maximum kinematic capacities of the CN machine:
risk of not respecting the desired qualities, machining under vibration, presence of
facets at the level of the machined surfaces, intense fluctuation of the feed rate bound
to the numerical capacities of the CNC unit, excesses of the desired machining
tolerance bound to the mode of the feed forward calculation, real behavior of the
machine highly different to that simulated......

What

To improve the quality and the precision of the complex surfaces obtained by
high speed machining and increase the service life of the CNC machine or Robots, it is
necessary to integrate the manufacturing parts process parameters as a boundary
condition in the calculation of the tool path: Dynamics of CNC machine axes, the
parameters (numerical and kinematics) defined in the CNC unit, parameters of the
smoothing mode, …

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 The new tool path calculation approach results in a significant improvement in
the accuracy and roughness of the free-form surface parts produced by high speed
machining (CNC machine and robot).

The suggested project aims at finding new mathematical models for calculating
the tool path integrating the drive controller parameters as a boundary condition (
Figure 1).

It consists in modeling of the machining operation parameters effect on the

machining quality which is directly bound to the machine kinematics, axis following
error and other parameters then transforming these models into algorithms. Finally, it
aims at integrating these algorithms in the loop of the tool path calculation, kinematics
simulation and in the post processors.

Figure 1 : proposed project

The suggested new software belongs to industry 4.0.

It allows to :

1) Limit the machine vibration.

2) Limit the feed rate fluctuation.

3) Ensure high accuracy: avoid the contour deviation bound to the

dynamics axes motion and the numerical limit capacities of the CNC unit

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 4) Simulate the dynamic motion of the CNC machine taking into account
the effect of all the environmental elements of the machining operation (parameter of
the CNC unit, smoothing mode,…).

5) Helps the programmer to:

a) Readjust the parameters defined in the cam software.

b) Readjust the parameters defined in CNC unit: max axis jerk, max axis
acceleration, feed forward control,...

c) Optimal choice of smoothing parameters

6) Create modifications at the NC file in order to improve the machining quality.

What has been accomplished so far?

1) The study of the effect of the drive controller parameters (CNC UNIT),
the dynamic axes motion, inertia variation of the axes motion, the parameters of the
smoothing mode (local and global) on axis following error (offset between the set
point tool path and the actual) and machine vibration in the field of high-speed
milling of the freeform surfaces.

2) Integration and programming in MATLAB of the smoothing mode as a

boundary condition for calculating the tool path.

3) Analytical modeling of the feed forward control of the CNC Unit as a

boundary condition for calculating the tool path and development of the algorithm.

4) experimental validation of new approaches

5) Other parameters are being modeled (axes inertia variation, dynamic

adaptation,…)

What are real life benefits?

1) Machining with the maximum capacity of CNC machines.

2) Taking into account the movement errors bound to the dynamics of the
CNC machine, the parameters of the NC unit and the servo-control loop of the axes
in the calculation of the tool path by CAM software.

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 3) Ensuring maximum precision and surface finish

Machining without vibration

4) Intelligent CAM software: the software can offer improvement

solutions to the programmer.

5) Integrate CAM software in factory 4.0

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 List of Partners
I) Industrial Partners
1- From Germany :
• Module work (www.moduleworks.com)
2- From Italy
• OPENCOM (www.opencom-italy.org)
3- From Spain
• EASYPYME.TECH (https://businesscure.org/)
4- From Tunisia
• AMECAP (www.amecap.tn (contact@amecap.com)
• MECANOPRECIS (http://www.mecanoprecis.com)
• DK SOFT (www.dksoft.tn)
• ECL (ecl.com.tn - ecl@gnet.tn)
• The Tunisian Engineers Order : OIT (www.oit.org.tn -

handassa@oit.org.tn - communication@oit.org.tn)

• Wemake3D (www.wemake.tn)
• SIM3D(https://www.sim3d-engineering.com)
II) University Partners
1- From Tunisia
• Higher Institute of Technology Studies of Sfax
(https://isetsf.rnu.tn - isetsf@isetsf.net )
• Higher Institute of Technology Studies of Kef
(http://www.isetkf.rnu.tn - isetkf@isetkf.rnu.tn)

• University of sfax (http://univ-sfax.tn)

 • The University of Monastir (http://www.um.rnu.tn/fr - um@um.rnu.tn)
• Vocational training center of Excellence in Aeronautical
Industry Professions (http://atfp.tn)
2- From France:
• University of Artois (http://www.univ-artois.fr/artois-university)

• National School of Engineers of Tarbes-french

(https://www.enit.fr/fr/index.html)
• Automated Production Research Laboratory (LURPA)
3- From Norway
• UiT the Arctic University of Norway (https://en.uit.no/startsida)
4- From Greece
• International Hellenic University, Department of Mechanical
Engineering & Department of Science and Technology
(https://www.ihu.gr/en/undergraduate-studies)
5- From czech republic
• Technical University of Liberec (https://www.tul.cz/en/home-page)
6- From Uzbekistan
• Fergana Polytechnic Institute – FerPI (FPI)
(https://www.ferpi.uz/)