Closed Loop Manufacturing 4.0

该项目提出了一个闭环制造过程与基于物理的仿真模型，在线

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.