Tool replacement and machining optimization for the drill process

点击翻译按钮获取中文摘要

This project specifically concerns a drill process at Hitachi Power Systems Canada Ltd., Saskatoon (http://www.hitachi.sk.ca/; hereafter Hitachi), a key facility for the manufacturing of various heavy products, such as heat exchangers. The drill process is used to drill over thousands of tight-tolerance holes on the workpieces for the production of heat exchangers. In the process, it is vital to ensure the drill or cutting tool used is in good condition as the use of worn-out cutting tools leads to a dramatic decline in accuracy, and also potentially damages both the machining tool equipment and the workpiece. On the other hand, replacing drills prematurely adds machining costs. As such, replacing cutting tools at the appropriate time is important for improving the automation of machining processes, increasing manufacturing productivity, and minimizing machining costs. This project aims to establish an on-line tool wear monitoring system and, based on these measurements, develop methods to determine the time when the drills need to be replaced as well as cutting conditions that maximize tool lifetime while ensuring hole accuracy. The success of this project will have immediate technological and economic benefits to Hitachi and other Canadian industries that use their products. The project will also generate new knowledge on manufacturing automation while training graduate students to meet the increasing demand for highly qualified personnel in the Canadian manufacturing sector.