SBIR Phase I: Intelligent Tool Wear Monitoring
SBIR 第一阶段:智能刀具磨损监测
基本信息
- 批准号:0810434
- 负责人:
- 金额:--
- 依托单位:
- 依托单位国家:美国
- 项目类别:Standard Grant
- 财政年份:2008
- 资助国家:美国
- 起止时间:2008-07-01 至 2009-06-30
- 项目状态:已结题
- 来源:
- 关键词:
项目摘要
This Small Business Innovative Research Phase 1 project will investigate the confluence of process verification and tool wear technologies. Process verification - physics-based analysis and optimization of the machining process and sequel to purely geometric NC verification - can significantly improve the reliability and productivity of 21st Century manufacturing. Physics-based systems are based on tool force modeling and depend critically on input process model parameters called cutting energies. As the tool wears, these cutting energies and associated tool forces can double or triple, invalidating recommended cutting conditions based on sharp tool parameters, leading to broken tooling and disruptions in manufacture. This project will monitor spindle power to determine the cutting energies in situ, providing accurate updated model parameters and tool forces. Most importantly, in addition to providing reliable tool forces, the updated cutting energies may provide valuable tool wear information. In contrast to current commercial tool monitoring systems, the proposed system does not require laborious user-directed learning experiments. Following on some preliminary experiments, this effort will investigate whether the absolute value and time dependence of the cutting energies can be used to inform the user of the dominant wear mechanism, the extent of the tool wear and the expected remaining tool life. NC verification (virtual machining validating the part geometry) has become an ubiquitous technology. Process verification, based on tool force modeling, in principal can provide valuable guidance in setting optimal machining conditions. In practice, very few such systems have been sold, for three reasons. 1 The available systems focus on tool forces and few, if any, machinists know how to choose optimal force profiles. 2 Those tool forces, if based on sharp tool model parameters, are not reliable as the tool inevitably wears. 3 The primary market competitors have a small direct sales force, reaching only a limited market. In contrast, 1 the proposed process verification system will interface with machinist-friendly terms such as CNC performance limits and desired surface accuracy. 2 The technical solutions developed under this project will integrate with existing software-only process verification products to include reliable, updated tool forces as the tool wears. The integrated products will assist the machinist in selecting cutting conditions where more desirable wear mechanisms (flank wear) dominate and, if the technical program is successful, provide valuable estimates of the remaining tool life. If successful, this project could have a significant commercial impact on global 21st century manufacturing operations.
这个小型企业创新研究第一阶段项目将调查工艺验证和刀具磨损技术的融合。工艺验证--对加工过程进行基于物理的分析和优化,是纯几何NC验证的续篇--可以显著提高21世纪制造业的可靠性和生产率。基于物理的系统建立在刀具力模型的基础上,并严重依赖于被称为切割能量的输入过程模型参数。随着刀具的磨损,这些切割能量和相关的刀具力可能会增加一倍或三倍,从而使基于锋利刀具参数的推荐切割条件失效,从而导致刀具断裂和制造中断。该项目将监测主轴功率,以确定现场切割能量,提供准确的更新模型参数和刀具力。最重要的是,除了提供可靠的刀具力之外,最新的切削力还可以提供有价值的刀具磨损信息。与目前的商业工具监控系统相比,该系统不需要费力的用户指导的学习实验。在一些初步实验之后,这项工作将调查是否可以使用切割能量的绝对值和时间相关性来告知用户主要的磨损机制、刀具磨损的程度和预期的刀具剩余寿命。NC验证(虚拟加工验证零件几何)已经成为一种普遍存在的技术。建立在刀具力模型基础上的工艺验证,原则上可以为设定最佳加工条件提供有价值的指导。实际上,这类系统的销量很少,原因有三个。1现有的系统侧重于刀具力,几乎没有机械师知道如何选择最佳的力轮廓。2如果基于锐利的刀具模型参数,这些刀具力是不可靠的,因为刀具不可避免地会磨损。3初级市场竞争对手的直销队伍很小,只能进入有限的市场。相比之下,1拟议的工艺验证系统将与机械工人友好的术语接口,如数控系统的性能限制和所需的表面精度。2在该项目下开发的技术解决方案将与现有的纯软件过程验证产品相结合,以便在工具磨损时包含可靠的、更新的工具力。集成的产品将帮助机械师选择以更理想的磨损机制(后刀面磨损)为主的切割条件,如果技术计划成功,还将提供对剩余刀具寿命的有价值的估计。如果成功,这个项目可能会对21世纪的全球制造业务产生重大的商业影响。
项目成果
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Donald Esterling其他文献
Donald Esterling的其他文献
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{{ truncateString('Donald Esterling', 18)}}的其他基金
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- 资助金额:
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