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Toolpath Sum PDF

1. The goal of this research is to improve NC machine tool productivity by integrating geometric and mechanistic cutting process models with the machine controller to optimize toolpaths in real-time using sensor feedback. 2. If successful, it will fundamentally change the architecture of NC machine tools by allowing them to use high-level part descriptions instead of low-level G-codes, greatly decreasing prototype production time. 3. The research will develop integrated cutting models, use sensors for real-time self-calibration, compare actual and predicted cutting forces, and experimentally compare the new methods to current best practices.

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42 views

Toolpath Sum PDF

1. The goal of this research is to improve NC machine tool productivity by integrating geometric and mechanistic cutting process models with the machine controller to optimize toolpaths in real-time using sensor feedback. 2. If successful, it will fundamentally change the architecture of NC machine tools by allowing them to use high-level part descriptions instead of low-level G-codes, greatly decreasing prototype production time. 3. The research will develop integrated cutting models, use sensors for real-time self-calibration, compare actual and predicted cutting forces, and experimentally compare the new methods to current best practices.

Uploaded by

suhas_sna
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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PROJECT SUMMARY

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Toolpath Optimization by Real-time Application
of an Integrated Geometric/Mechanistic Model
The goal of this research is to improve the productivity of Numerically Controlled (NC)
machine tools. If the research is successful it will fundamentally change the architecture
of NC machine tools. Models of the cutting process will be integrated with the NC
machine controller. Sensor feedback will be used to monitor the process and
continuously improve the model accuracy through real-time self calibration. Machine
tool productivity will be increased, but the associated improvements in the product
development process may be of greater long term significance. Machine tool controllers
which use these methods will be capable of using high level part descriptions for input as
opposed to the low level "G-codes" that are currently in common usage; an attribute that
should greatly decrease the overall time required to produce prototypes on NC machines.
Specific elements of the research include:
1. Development of an experimental test facility by retrofitting a 5 axis NC milling
machine with an Open Architecture Controller (OAC).
2. Integrated geometric/mechanistic models of cutting on the OAC which are efficient
enough to run in "real-time" mode. The models will be used to calculate optimal
cutting conditions. Sensors on the machine tool will be used to perform continuous
self-calibration of model parameters.
3. Continuous real-time comparison of actual and model-predicted cutting forces and the
development of corrective actions to compensate for excessive differences.
4. Experimental comparisons between our methods and current "best practice"
approaches. Complex sculptured surface programs developed by expert NC
programmers at our industrial partner will be used.
5. Investigate trade-offs between model complexity, algorithm efficiency and
quantifiable process improvements in machining time and part quality.
Different levels of algorithm complexity will be investigated. We intend to explore the
use of two machining models: a simple volumetric model and a more exact integrated
geometric/mechanistic model. We will also explore the use of four different strategies
for using the models to optimize cutting conditions, ranging from a simple "chip-load
leveling" approach to a very complex method which accounts for the effect of tool
deflections on part dimensional tolerances. All of these methods can be implemented in
either an "off-line" or "on-line" mode. In the "off-line" mode, cutting conditions are
calculated prior to machining using "best guesses" for model coefficients. In the "online" mode, model coefficients are obtained from real-time measurement of cutting
conditions. Experimental results will be used to quantify trade-offs between the
complexity of the methods and the improvements in process efficiency.
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