Closed Loop Manufacturing 4.0

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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.