Toolpath Optimization by Real-time Application of an Integrated Geometric/Mechanistic Model

这项研究的目标是提高数控（NC）机床的生产率。切割过程的模型将与数控机床控制器集成。传感器反馈将用于监控过程，并通过实时自校准不断提高模型精度。使用这些方法的机床控制器将能够使用高级零件描述作为输入，而不是目前常用的低级“g代码”，这一属性将大大减少在数控机床上生产零件所需的总体时间。具体研究内容包括：(1)采用开放式结构控制器（OAC）改造五轴数控铣床，开发实验测试设备。(2)基于OAC的综合几何/力学模型，该模型能够以“实时”模式运行。该模型将用于计算最佳切削条件。机床上的传感器将用于对模型参数进行连续的自校准。(3)持续实时比较实际和模型预测的切削力，并制定纠正措施，以补偿过大的差异。(4)这些方法与当前“最佳实践”方法之间的实验比较。将使用由工业合作伙伴的NC编程专家开发的复杂雕刻表面程序。与目前的数控控制相比，该研究将在加工生产率和产品质量方面提高数控加工性能。五轴数控铣床上的开放式架构控制器可以在接近真实工业环境的环境中测试模型。

DMI-9872575Jerard The goal of this research is to improve the productivity of Numerically Controlled (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 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 parts 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 these methods and current "best practice" approaches. Complex sculptured surface programs developed by expert NC programmers at an industrial partner will be used. The research should lead to improved NC machining performance compared with the present NC control, in terms of machining productivity and product quality. The open-architecture controller on a 5-axis NC milling machine enables testing of the model in an environment close to real industrial setting.