MRI/ RUI: Acquisition of Manufacturing Systems for Quality Assurance in Precision Machining Processes using Data Mining

该主要研究仪器奖将允许购买两台计算机数控机床，特别是一台立式加工中心和一台车削中心。该合同还将允许采购切削力测力计、振动和声发射传感器以及激光和球棒校准系统。该设备将用于研究机床误差的测量和建模，以进行误差补偿，并通过多个传感器收集过程数据，以识别切削条件，材料性能和零件质量之间的相关性，以优化制造工艺。该设备将实现智能制造系统的开发，该系统将完全将质量保证集成到精密加工过程中，并实现完全的制造自动化，不产生任何缺陷，同时显著提高生产率、零件质量并降低制造成本。实时过程控制将减少废品率、返工率、交货期和传统的非增值检验活动，从而提高零部件制造商的竞争力。此外，该设备将为制造专家提供动手本科生研究和教育的机会。七门课程将受到制造课程中设备的影响，并将在奖励期间使西肯塔基大学的400多名学生受益。在此资助下发展的精密加工实验室将用于区域高中和初中技术教育学生的技术竞赛。影响的范围是广泛的，因为提出的研究包括铣削，车削和钻孔工艺。其结果不仅有利于机床行业，而且有利于汽车和航空航天工业以及其他离散零件制造商。

This Major Research Instrumentation award will enable the purchase of two computer numerical control machine tools specifically a vertical machining center and a turning center. The award will also enable the purchase of a cutting force dynamometer, vibration and acoustic emission sensors as well as laser and ballbar calibration systems. This equipment will be used to conduct research in measuring and modeling machine tool errors for error compensation and collect process data via multiple sensors to identify the correlation between cutting conditions, material properties and part quality for optimization of manufacturing processes.This equipment will enable development of an intelligent manufacturing system, which will fully integrate quality assurance into precision machining processes and result in full manufacturing automation, yielding no defects coupled with a significant improvement in productivity, part quality and reduced manufacturing costs. The real-time process control will enable reduction in scrap, rework, lead-time, and conventional non value-added inspection activities, and thereby will increase competitiveness of part manufacturers. In addition, the equipment will provide opportunities for hands-on undergraduate research and education for the manufacturing specialist. Seven courses will be impacted by the equipment in the manufacturing curriculum and will benefit over four hundred students at Western Kentucky University during the award period. The precision machining laboratory to be developed under this grant will be used during technology competition for regional high school and middle school technology education students. The scope of the impact is broad in that the proposed research encompasses milling, turning, and drilling processes. The results will benefit not only machine tool industry but also automotive and aerospace industries and other discrete part manufacturers.