Toolpath Optimization by Real-time Application of an Integrated Geometric/Mechanistic Model

DMI-9872575Jerard本研究的目标是提高数控机床的生产率。切割过程的模型将与NC机床控制器集成。传感器反馈将用于监控过程，并通过实时自校准不断提高模型精度。使用这些方法的机床控制器将能够使用高级零件描述进行输入，而不是目前普遍使用的低级“G代码”--这一属性应该会大大减少在NC机床上生产零件所需的总体时间。研究的具体内容包括：(1)通过使用开放式体系结构控制器(OAC)对五轴数控铣床进行改造，开发了一种实验测试设备。(2)集成了OAC上的几何/机械切割模型，这些模型的效率足够高，可以在“实时”模式下运行。这些模型将被用来计算最佳的切割条件。机床上的传感器将用于执行模型参数的连续自校准。(3)连续实时比较实际切削力和模型预测切削力，并制定纠正措施以补偿过大的差异。(4)这些方法与当前“最佳实践”方法的实验比较。将使用由工业合作伙伴的专业NC程序员开发的复杂雕塑曲面程序。在加工效率和产品质量方面，与目前的数控控制相比，该研究应该能够提高数控加工的性能。五轴数控铣床上的开放式控制器使模型能够在接近真实工业环境的环境中进行测试。

DMI-9872575Jerard The goal of this research is to improve the productivity of Numerically Controlled (NC) machine tools. Models of the cutting process will be integrated with the NC machine controller. Sensor feedback will be used to monitor the process and continuously improve the model accuracy through real-time self-calibration. Machine tool controllers which use these methods will be capable of using high-level part descriptions for input as opposed to the low-level "G-codes" that are currently in common usage - an attribute that should greatly decrease the overall time required to produce parts on NC machines. Specific elements of the research include: (1) Development of an experimental test facility by retrofitting a 5-axis NC milling machine with an Open Architecture Controller (OAC). (2) Integrated geometric/mechanistic models of cutting on the OAC which are efficient enough to run in "real-time" mode. The models will be used to calculate optimal cutting conditions. Sensors on the machine tool will be used to perform continuous self-calibration of model parameters. (3) Continuous real-time comparison of actual and model-predicted cutting forces and the development of corrective actions to compensate for excessive differences. (4) Experimental comparisons between these methods and current "best practice" approaches. Complex sculptured surface programs developed by expert NC programmers at an industrial partner will be used. The research should lead to improved NC machining performance compared with the present NC control, in terms of machining productivity and product quality. The open-architecture controller on a 5-axis NC milling machine enables testing of the model in an environment close to real industrial setting.