Minimization of Force Model Uncertainty for CNC Milling Process Improvement

本研究的目的是通过使用嵌入在刀具中的无线传感器来减少加工模型的不确定性。方法是研究原位模型校准的方法，以足够的频率进行，使模型精度保持在可接受的误差范围内。将探索基于切削功率、时域力和扭矩信号以及频域信号的方法。将研究采用无线蓝牙传输工具安装传感器的新型传感器技术，以测量切削扭矩和力。线性度，信噪比和串扰将被评估。无线传感器数据与机器过程数据的时间同步对于执行精确的模型校准是必要的。如果成功，这项研究将大大提高机床的可靠性，使他们对自己的工艺能力有一个自我认识。降低模型不确定性的方法将提高基于物理模型的计算机数控工艺规划的实用性，从而提高零件质量和加工效率。可以选择加工策略和切削条件（主轴速度和进给）来适当地反映机床的当前能力。无线传感器将在工业和学术研究中得到广泛应用。该项目与美国国家标准与技术研究所制造工程实验室和集成制造计划的目标一致，集成制造计划是一个由工业、学术和政府合作伙伴组成的公共/私人财团，旨在加强美国的制造业社区。

The objective of this research is to reduce the uncertainty of machining models through the use of wireless sensors embedded in the cutting tool. The approach is to investigate methods for in-situ model calibration, performed with sufficient frequency, such that model accuracy is maintained within acceptable error bounds. Methods based on cutting power, time domain force and torque signals, and frequency domain signals will be explored. New sensor technology using wireless Bluetooth transmission of tool mounted sensors will be investigated to measure cutting torque and force. Linearity, signal to noise ratios, and cross talk will be evaluated. Time synchronization of the wireless sensor data with the machine process data will be necessary to perform accurate model calibrations.If successful, this research will greatly improve the reliability of machine tools by giving them a self-knowledge of their process capabilities. Methods for decreasing model uncertainty will improve the utility of physics based models for computer numerical control process planning leading to greater part quality and higher machining efficiency. Machining strategies and cutting conditions (spindle speeds and feeds) can be chosen to appropriately reflect the current capabilities of the machine tool. Wireless sensors will be developed which will be broadly used in both industry and academic research. This project is consistent with the goals of the Manufacturing Engineering Laboratory at the National Institute of Standards and Technology and the Integrated Manufacturing Initiative, a public/private consortium of industry, academic, and government partners designed to strengthen the nation's manufacturing community.