Closed Loop Manufacturing 4.0

该项目提出了一个闭环制造过程，具有基于物理的仿真模型，在线监测和实时过程控制，符合工业4.0原则。加工过程将在物理生产之前在虚拟环境中进行模拟，并存储在云端或数据库中。从数控系统的固有数据中获取切削力、振动等实时加工信息。预模拟结果和实时测量将结合使用，以调整加工条件，抑制颤振，防止过度刀具磨损，避免机器过载，同时最大限度地减少生产周期时间。因此，所谓的数字孪生加工系统，本项目的具体目标包括：（1）利用主轴电流识别刀尖动态特性以消除颤振，（2）利用进给驱动电流在线监测刀具磨损，（3）利用刀具磨损的实时性和动态性，（4）利用刀具磨损的实时性和动态性，（5）利用刀具磨损的实时性和动态性，（6）利用刀具磨损的实时性和动态性，（7）利用刀具磨损的实时性和动态性，（8）利用刀具磨损的实时性和动态性，（9）利用刀具磨损的实时性和动态性，（10）利用刀具磨损的实时性和动态性，（3）提高生产率的轨迹规划和进给速度优化：（4）切削力监控中的进给动力学辨识;以及（5）将算法集成到商业上可行的加工模拟和监控软件中。项目结果将用于减少加工时间和零件报废通过增强智能加工功能来提高速度。一个商业产品将被开发和应用于大批量生产，以及小批量和高度定制类型的零件。该项目预计将使航空航天、汽车、工业机械和生物医学设备等关键制造业受益。

This project proposes a Closed Loop Manufacturing process with physics-based simulation models, onlinemonitoring, and real-time process control in accordance with Industry 4.0 principles. The machining processwill be simulated in a virtual environment ahead of physical production and stored in the cloud or in adatabase. Real-time machining information, such as cutting force and vibration, will be obtained from inherentCNC (Computer Numerical Control) system data. The pre-simulated result and real-time measurement will beused in conjunction to adjust the machining conditions for suppressing chatter vibrations, preventing excessivetool wear, and avoiding machine overloads, while minimizing the production cycle time. As a result, aso-called digital twin machining system (i.e. combination of simulation and real-time) will be developed withcore functionalities in simulation, monitoring, and self-optimization.Specific aims of this project include: (1) Identification of tool tip dynamics using spindle current for chatteravoidance; (2) Online tool wear monitoring using the feed drive current; (3) Trajectory planning and feedrateoptimization 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 monitoringsoftware.The project results will be used to reduce machining time and part scrap rates by enhancing intelligentmachining feature. A commercial product will be developed and applied for high volume production, as well asfor low volume and highly customized type of parts. The project is expected to benefit key manufacturingsectors such as aerospace, automotive, industrial machinery, and biomedical devices.