Development of Advanced Machine Tool to Realize Autonomous Machining Operation Unconstrained by NC program

研制了一种先进的数控机床，实现了不受数控程序约束的自主加工。随后进行了成功的实验验证。为实现柔性加工操作的切削参数动态生成，开发了柔性工艺与作业规划系统。灵活的工艺和作业计划系统可以从总出卸量（TRV）生成生产计划。TRV是从产品的初始形状和成品形状中提取出来的，表示为3D CAD模型。此外，还开发了一种数字仿形铣削技术，用于数控机床的实时控制。实现了自主机床样机，并成功进行了实验切削试验。开发了一种能够实时预测切削扭矩的虚拟加工仿真器。此外，还提出了一种通过检测数控控制器中的控制信号来检测实际切削转矩的监测技术。在开发的智能监控系统中，可以将实际切削扭矩与预测切削扭矩进行比较。将加工过程中的实际扭矩与预测扭矩进行比较，有助于发现加工故障或识别加工状况。开发的数字仿铣削系统能够实时生成刀具轨迹，并允许在加工过程中改变切削参数。此外，提出了一种改变切削参数的控制算法，以避免加工故障，保持加工平稳运行。实现了一种将数字仿形铣削系统与控制算法相结合的自适应控制系统。在实验切削试验中，不仅可以适当地改变进给速度，而且可以适当地改变轴向和径向深度，以保持稳定的加工运行。少

Required functions for an advanced NC machine tool, which realizes autonomous machining operation unconstrained by NC program, have been developed. Following experimental verifications were performed successfully.1. Direct machining operation controlled by flexible process and operation planning systemA flexible process and operation planning system was developed to generate cutting parameters dynamically for flexible machining operation. The flexible process and operation planning system can generate the production plan from the Total Removal Volume (TRV). The TRV is extracted from initial and finished shapes of the product represented as 3D CAD models. In additional, a technique called digital copy milling was developed to control the NC machine tool in real time. A prototype of autonomous machine tool was implemented, and the experimental cutting tests were carried out successfully.2. Intelligent monitoring to recognize machining conditionsA virtual machining simulator, which predic … More ts cutting torque in real time, was developed. In addition, a monitoring technique, which detects actual cutting torque by detecting the control signals in NC controller, was developed. In the intelligent monitoring system developed, the actual cutting torque can be compared with the predicted one. The comparison of the actual and predicted, torques during machining operation is very helpful to detect machining trouble or recognize machining conditions.3. Adaptive control of cutting parameters to keep stable machining operationThe digital copy milling system developed can generate the tool paths in real time and it permits to change the cutting parameters during the machining operation. In addition, a control algorithm to change cutting parameters for avoiding machining trouble and keeping stable machining operation was proposed. An adaptive control system, which is integrated the digital copy milling system and the control algorithm, was implemented. In the experimental cutting tests, not only the feed speed but also the axial and radial depths can be changed suitably to keep stable machining operation. Less