Closed Loop Manufacturing 4.0

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This project proposes a Closed Loop Manufacturing process with physics-based simulation models, online**monitoring, and real-time process control in accordance with Industry 4.0 principles. The machining process**will be simulated in a virtual environment ahead of physical production and stored in the cloud or in a**database. Real-time machining information, such as cutting force and vibration, will be obtained from inherent**CNC (Computer Numerical Control) system data. The pre-simulated result and real-time measurement will be**used in conjunction to adjust the machining conditions for suppressing chatter vibrations, preventing excessive**tool wear, and avoiding machine overloads, while minimizing the production cycle time. As a result, a**so-called digital twin machining system (i.e. combination of simulation and real-time) will be developed with**core functionalities in simulation, monitoring, and self-optimization.**Specific aims of this project include: (1) Identification of tool tip dynamics using spindle current for chatter**avoidance; (2) Online tool wear monitoring using the feed drive current; (3) Trajectory planning and feedrate**optimization for productivity increase; (4) Identification of feed drive dynamics for cutting force monitoring;**and (5) Integration of the algorithms into a commercially viable machining simulation and monitoring**software.**The project results will be used to reduce machining time and part scrap rates by enhancing intelligent**machining feature. A commercial product will be developed and applied for high volume production, as well as**for low volume and highly customized type of parts. The project is expected to benefit key manufacturing**sectors such as aerospace, automotive, industrial machinery, and biomedical devices.