Intelligent tool-holding with feedback control for metal-cutting machine tools

该项目将创造一种新产品，可以自动提高生产机床镗孔操作的表面光洁度。它结合了优化传感器位置的机械设计与先进的建模，以确保最佳和稳健的校正值。它建立在Innovate UK项目的成功基础上，该项目名为“金属切削机床的智能刀架”，在该项目中，双方都展示了使用安装在刀架上的振动传感器的输入来预测车削孔表面粗糙度的可行性。新项目的创新之处在于，我们在车削操作中安装了用于深孔钻孔的传感器，该传感器将为加工参数的自动调整提供反馈，而不是由经验丰富的操作员在加工过程中手动调整。这将提高加工过程中的生产率。创新的主要领域，按重要性排序如下：1。采用先进的表面预测算法，并产生在制造环境中具有鲁棒性的校正模型，旨在提高表面光洁度。为数据采集、建模和反馈提供一种通用方法，以证明该技术可用于不同尺寸的工具和不同机器的自动控制。改进现有的最先进的模型，允许仅基于刀架的数据进行控制，而不是昂贵的安装在工具上的传感器，这在工业中是不常见的。该项目将提供五个演示，以展示该系统应用于不同机床类型和镗杆尺寸的能力。

This project will create a new product that will automatically improve the surface finish of boring operations in production machine tools. It combines mechanical design for optimising sensor location with advanced modelling to ensure optimal and robust correction values.It builds on the successful Innovate UK project, "Intelligent tool-holding for metal cutting machine tools" where both partners showed the feasibility of predicting the surface roughness of a turned bore when using inputs from a vibration sensor mounted in the tool holder.The innovation in the new project is that we are mounting sensors in the tool holder for deep hole boring on turning operations that will provide feedback for automatic adjustments of machining parameters, as opposed to an experienced operator having to manually adjust during the process. This will lead to improved productivity in the machining process.The main areas of innovation, in order of importance, are:1. To take the advanced surface prediction algorithms and produce corrective models that are robust in manufacturing environments and targeted at improving surface finish.2. To produce a generalised approach to the data acquisition, modelling and feedback to prove that the technology can be used for automatic control with different sized tooling and on different machines.3. To improve the existing state-of-the-art models to allow control based only on data from the tool holder, rather than expensive tool-mounted sensors, which are not commonly available in industry.The project will deliver five demonstrators to show the ability of the system to be applied on different machine tool types and boring bar sizes.