Dynamic modeling and optimal trajectory planning for multi-axis contour machining for aerospace parts

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This project targets the development of:- New time-optimal trajectory generation algorithms for 2½ -, 3-, and 5-axis machining operations;- Rapid identification techniques, for constructing virtual models of CNC machine tool drives in minimum downtime to production machinery;- Flexible Multi-Body Dynamic (FMBD) modeling methods, to build highly accurate bottom-up Virtual Prototypes (VP) of multi-axis machines, which can be used for process optimization.As developed, these technologies will be transferred to the industry partner, Pratt & Whitney Canada (P&WC) in the form of new modules and models that can be used inside commercially available software, Virtual CNC (VCNC). This will enable P&WC engineers and research personnel to accurately simulate and optimize the dynamic response of multi-axis machine tools during high speed contouring operations, thus enabling aerospace parts with complex geometry to be produced in shorter cycle time and increased productivity. By enabling P&WC to produce safety-critical components of gas turbine engines at higher productivity rates, the proposed research will help strengthen Canada's leadership in high-tech aerospace manufacturing.The technologies developed will be pervasive in the sense that they can also be applied to boost the productivity of multi-axis manufacturing operations for other complex parts produced in aerospace, automotive, electronics, die and mold, and biomedical device industries, for which high-speed high-accuracy motion along pre-defined contours is required. Overall, the project will support cutting edge research on trajectory optimization, system identification, and dynamic modeling at the University of Waterloo (UW), by helping train two doctoral students (PhD's), one post-doctoral fellow (PDF), and one research associate (RA).