Closed Loop Manufacturing 4.0

该项目提出了一种基于物理仿真模型的在线闭环制造工艺 根据行业4.0原则进行监控和实时过程控制。机械加工工艺 将在物理生产之前在虚拟环境中进行模拟，并存储在云中或 数据库。实时加工信息，如切削力和振动，将从固有的 (计算机数字控制)系统数据。预模拟结果和实时测量结果将 用于调整加工条件，以抑制颤振，防止过度振动 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，一个 所谓的数字双加工系统(即仿真和实时相结合)将以 模拟、监控和自我优化方面的核心功能。 本项目的具体目标包括：(1)利用主轴电流进行抖动识别刀尖动力学 避免；(2)利用进给驱动电流在线监测刀具磨损；(3)轨迹规划和进给速度 优化提高生产率；(4)用于切削力监测的进给驱动动力学辨识； 以及(5)将算法集成到商业上可行的加工模拟和监控中 软件。 该项目的成果将用于通过增强智能来减少加工时间和零件废品率 加工特征。将开发并应用于大批量生产的商业产品，以及 适用于小批量和高度定制化类型的零件。该项目预计将使关键制造业受益 航空航天、汽车、工业机械和生物医疗设备等行业。

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.