QUESTION 2 Study a manufacturing or industrial process of your choice. 2.1 Report on the level...

QUESTION 2

Study a manufacturing or industrial process of your choice.

2.1 Report on the level of automation and various actuators used giving justification. (10)

2.2 Identify processes where adaptive, feedforward and regulatory control are used. (10)

2.2 Explain the components used safety monitoring, diagnostics and how maintenance is

achieved.

Solutions

Expert Solution

2.1) A lathe spindle shaft manufacturing is analysed. It is processed in a CNC lathe with Fanuc control. The design engineer give the dimensions to the shop floor. The CNC codes are generated with The help of a software Master CAM, and is fed into machine tool through usb interface. Thus avoiding human interfere.

Now the process is verified manually and started machining. A spindle is specified with its diameter, length and surface finish required.

Non contact type profile meter readings are used for monitoring surface finish obtained. This helps to avoid re working, if we are checking the surface finish using a conventional profilo meter.

Rotory actuator in spindle is responsible for holding the workpiece while machining. Servomotors coupled with ball screws for linear motion.

2.2) The cutting force mainly depends on depth of cut, feed and speed. So monitoring cutting force is becesary as a non optimal cutting force may deteriorate surface finish. Hence adaptive control which monitor cutting force with the help of a dynamometer and a closed loop feed back system is used. as mentioned earlier non contact type profile meter readings are used for monitoring surface finish.

2.3) Accoustic emission sensors are used for monitoring machine tool. AE sensor detects sound waves produced during machining is detected vibrations are analysed. This detects high energy waves formed while machining. They are mounted easily on machine toolThis does not affect the stiffness and integrity of system.

Accelerometers installed on lathe helps to detect vibration amplitudes. Hence we may change process parameters to get desired output

samet mamat answered 2 years ago

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