Dynamic Evaluation of Machine Tool Process Capability

本研究的主要目的是探讨动态测量机床加工能力的新技术和策略。第二个目的是研究利用加工能力信息来准确估计加工成本。该研究方法将实时传感器数据与独特的切削力过程模型相结合，既准确又计算效率高。加工能力将通过比较测量的切削力和并发模型仿真结果来估计。开放式机床控制器将用于收集和存储测量数据，运行模型仿真，并动态更新过程能力。广泛的实验研究将集中在三个被认为是最难表征的参数上：刀具跳动、刀具偏转和刀具磨损。通用性将通过实验矩阵进行测试，该实验矩阵包括各种不同的切削条件，刀具类型以及黑色和非黑色合金材料。这一研究项目的成功完成将提高机床的可靠性、精度和效率，使机床对其加工能力有了自我认识。加工能力信息还可用于准确估计加工成本，从而为设计人员提供有关其设计选择的成本含义的有价值的反馈。特定机床的加工能力可以智能匹配零件公差要求，以确保无缺陷生产。随着时间的推移，通过调整切削策略和条件来响应不断变化的加工能力，可以保持零件质量。该项目还将支持国家标准与技术研究所的智能机器计划，并与集成制造计划的目标相一致，集成制造计划是一个由工业、学术和政府合作伙伴组成的公共/私人财团，旨在加强国家制造业社区。

The primary objective of this research is to investigate novel techniques and strategies for dynamically measuring the process capability of machine tools. A secondary purpose is to investigate the use of process capability information to accurately estimate machining costs. The research approach combines real-time sensor data with unique cutting force process models that are both accurate and computationally efficient. Process capability will be estimated by comparing measured cutting forces with concurrent model simulation results. An open-architecture machine tool controller will be used to collect and store measurement data, run model simulations, and dynamically update the process capability. Extensive experimental studies will focus on three parameters deemed to be the most difficult to characterize: tool runout, tool deflection and tool wear. Generality will be tested with an experimental matrix that includes a variety of different cutting conditions, cutter types, and ferrous and non-ferrous alloy materials.Successful completion of this research project would improve the reliability, accuracy and efficiency of machine tools by giving them self-knowledge of their process capabilities. Process capability information could also be used to accurately estimate machining costs, thereby providing valuable feedback to designers about the cost implications of their design choices. Process capabilities of a specific machine tool could be intelligently matched with part tolerance requirements to ensure defect free production. Part quality could be maintained over time by adjusting cutting strategies and conditions in response to changing process capability. This project will also support the Smart Machine Initiative of the National Institute of Standards and Technology and is consistent with the goals of the Integrated Manufacturing Initiative, a public/private consortium of industry, academic, and government partners designed to strength the nation's manufacturing community.