Robots have become an essential part of modern industries in welding departments to increase the accuracy and rate of production. The intelligent detection of welding line edges to start the weld in a proper position is very important. This work introduces a new approach using image processing to detect welding lines by tracking the edges of plates according to the required speed by three degrees of a freedom robotic arm. The two different algorithms achieved in the developed approach are the edge detection and top-hat transformation. An adaptive neuro-fuzzy inference system ANFIS was used to choose the best forward and inverse kinematics of the robot. MIG welding at the end-effector was applied as a tool in this system, and the weld was completed according to the required working conditions and performance. The parts of the system work with compatible and consistent performances, with acceptable accuracy for tracking the line of the welding path.
The additive manufacturing (AM) process or three-dimensional printing (3DP) process is making stereoscopic shapes using a layered system. There are several materials used for printing such as plastic, wood, metal as powder, filament, liquid, or others, and there are also different ways for printing. Recently, the focus has been on metal printing, but the problem is that the high energy used such as laser, electron beam, or high heat to melt the metal to print it as required. For this reason, the price of 3D printers for metal is very expensive. In this paper, the design and implementation of a 3D printer for metal parts production are worked. The work also includes making an experimental test for the new 3D printer and printing 3D metal parts without using heat. In this work, Tevo-Tarantula 3D printer has been modified in terms of software and hardware. Two new extruders are designed to inject the metal powder and adhesive, where the heat was removed from the extruder head and the printer bed. The metal powder extruder contains a powder reservoir, glass funnel, and access valve where controlled through the solenoid valve. The adhesive extruder is controlled using a simple hydraulics. The printing process was done by printing two layers of metal powder and a layer of adhesive depending on the desired shape to create 3D objects using the SolidWorks software. Different metal models were printed and these models were compared with the original design which was drawing by SolidWorks software. The difference between the actual model drawing and the printed parts is differences between (0.004 mm) for some parts to (2.3 mm) for other parts or the percentage of error is between (0.1%-4%) for the printed parts. However, the material can be used in high temperatures, where rubber materials cannot be used, and in applications requiring porosity.
In this paper the ability of fabricating laminate composites by manual layup was discussed. Heating method was used to manufacture the composites; heat was applied to approximately 12 hours with specific heat temperature. There were four types of laminate composites fabricated and studied in this research, containing Aluminum alloy 6061 as the common element in all types, two types of fibers; woven Carbon fiber with two different orientations: ±45°, ±60°, random fiberglass and with two types of resin; epoxy resin and polyester resin. Different types of composites were made to determine the effect of CNC milling machine to the measured surface roughness and for specified parameters. The weight fraction ratio of the fibers is 37%, polymer is 34% and 29% for Aluminum. The parameters selected are spindle speed, feed rate and depth of cut. The L9 Taguchi orthogonal arrays, signal to noise (S/N) ratio and analysis of variance (ANOVA) are selected to determine the effect of these parameters; it was analyzed by MINITAB 17 program. The results showed that the parameter were significant more to the epoxy resin specimens than polyester resin specimens. The optimal milling parameters for good surface finish for Aluminum – Carbon fiber composite are at 3000RPM, 1200mm/min, 1.2mm, and for Aluminum – Fiberglass composite are 5000RPM, 1800 mm/min, 2.0mm.
The additive manufacturing (AM) process or three-dimensional printing (3DP) process is making stereoscopic shapes using a layered system. There are several materials used for printing such as plastic, wood, metal as powder, filament, liquid, or others and there are also different ways for printing. Recently, the focus has been on metal printing, but the problem is that the high energy used such as laser, electron beam, or high heat to melt the metal to print it as required. For this reason, the price of 3D printers for metal is very expensive. In this paper, design and implementation of a 3D printer for metal parts production are worked. The work also includes making an experimental test for the new 3D printer and printing 3D metal parts without using heat. In this work, Tevo-Tarantula 3D printer has been modified in terms of software and hardware. Two new extruders are designed to inject the metal powder and adhesive, where the heat was removed from the extruder head and the printer bed. The metal powder extruder contains a powder reservoir, glass funnel, and access valve where controlled through the solenoid valve. The adhesive extruder is controlled using a simple hydraulics. The printing process was done by printing two layers of metal powder and a layer of adhesive depending on the desired shape to create 3D objects using the SolidWorks software.Different metal models were printed and these models were compared with the original design which was drawing by SolidWorks software. The difference between the actual model drawing and the printed parts is differences between (0.004 mm) for some parts to (2.3 mm) for other parts or the percentage of error is between (0.1% -4%) for the printed parts. However, the material can be used in high temperatures, where rubber materials cannot be used, and in applications requiring porosity.
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