A Novel Approach Towards High-Fidelity Machining Simulation

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dc.contributor.advisor Xu, X en
dc.contributor.author Abdul Kadir, Aini en
dc.date.accessioned 2012-12-13T19:57:16Z en
dc.date.issued 2012 en
dc.identifier.uri http://hdl.handle.net/2292/19762 en
dc.description.abstract In machining simulation, there is always a trade-off between high-level accuracy and an abstraction of reliance and a truthful simulation environment. Most research work has been devoted to developing precise models and algorithms, yet these still lack the ability to portray the true machining environment. They are based on ideal machine conditions resulting in an 'isolated' simulation environment. This is due to the difficulty of providing a simulation model with data at the shop-floor level. Adding to the challenge is the dynamic nature of many shop-floor activities. Machining parameters, cutting tools, workpieces and fixture orientations are not usually captured and considered in simulation. This is further compounded by the use of low-level Numerical Control data (G-code or CL data) that has inherent drawbacks such as being vendor-specific, possessing incomplete data, irreversible data conversions and a lack of accuracy. Hence, there is a need for higher-level input data to assist accurate machining process simulation; there is also a need to take into account the actual behaviour and real-time data of a machine setup. To address the above issues, this researcher developed a High-Fidelity Machining Simulation (HFMS) solution to cater for a high-fidelity machining simulation environment with the capacity to provide more realistic simulation for machining processes. The main goal is to bring simulation closer to CNC level and generate reliable and truthful simulation output with minimum modifications needed upon machining. To achieve this, STEP (STandard for Exchange of Product data) and STEP-NC (STandard for Exchange of Product data for Numerical Control) data models were enhanced in order to provide a comprehensive data structure that enables the integration between modelling design and control data. The status quo of the machine tool was captured by means of sensors and network protocols (e.g. MTConnect), to provide true data values of the Actual Machine Status, which was then utilised to assist the machining simulation tasks. The HFMS system has three operational phases; Pre-Machining, Machining Simulation and Post-Machining. The Pre-Machining phase aims to provide assistance to process planners or machinists for preparatory activities prior to machining simulation operations. Machining Simulation is the main interface where visualisation and simulation activities are performed, based on the information from the Pre-Machining and Post- Machining phase. The Post-Machining phase deals with knowledge-based data, with the help of the Machining History Database. The outcome of the research provides a universal, truthful, smart and better informed simulation environment. Up-to-date information obtained by the simulation supports the inter-working concept in a virtual-real systems relationship in which reduces the total setup operation time. The system has been validated with capabilities such as: (i) tool-path simulation can be adapted to a real machining setup; (ii) reliable NC codes that represent on-field machine status can be generated; (iii) non-proprietary machine control codes are utilised; (iv) physical testing trials can be eliminated; and (v) future simulation is improved. The system architecture guarantees that the information from a real machining environment can be used to increase the fidelity behaviour of a simulation system; this leads to the scenario of 'Smart Simulation for Smart Machining'. The research work presented in this thesis is based on eight published research articles, i.e. three journal papers and five conference papers. en
dc.publisher ResearchSpace@Auckland en
dc.relation.ispartof PhD Thesis - University of Auckland en
dc.rights Items in ResearchSpace are protected by copyright, with all rights reserved, unless otherwise indicated. Previously published items are made available in accordance with the copyright policy of the publisher. en
dc.rights.uri https://researchspace.auckland.ac.nz/docs/uoa-docs/rights.htm en
dc.rights.uri http://creativecommons.org/licenses/by-nc-sa/3.0/nz/ en
dc.title A Novel Approach Towards High-Fidelity Machining Simulation en
dc.type Thesis en
thesis.degree.grantor The University of Auckland en
thesis.degree.level Doctoral en
thesis.degree.name PhD en
dc.rights.holder Copyright: The Author en
pubs.elements-id 369891 en
pubs.record-created-at-source-date 2012-12-14 en

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