Intelligent tool-holding with feedback control for metal-cutting machine tools

该项目将创造一种新产品，将自动改善生产机床中钻孔操作的表面光洁度。它将优化传感器位置的机械设计与先进的建模相结合，以确保最佳和稳健的校正值。它建立在成功的Innovate UK项目“金属切割机床的智能刀架”的基础上，在该项目中，双方都展示了使用安装在刀架上的振动传感器输入来预测车削孔表面粗糙度的可行性。新项目的创新是，我们在车削操作中将传感器安装在深孔钻削的刀架上，这将为加工参数的自动调整提供反馈，而不是经验丰富的操作员在加工过程中必须手动调整。这将提高加工过程中的生产率。创新的主要领域按重要性排序为：1.采用先进的表面预测算法，产生在制造环境中稳健的、旨在改善表面光洁度的修正模型。提出一种通用的数据采集、建模和反馈方法，以证明该技术可用于不同尺寸刀具和不同机床的自动控制。为了改进现有最先进的模型，使控制只基于刀具夹具的数据，而不是昂贵的工具安装传感器，这在行业中并不常见。该项目将提供五个演示程序，以展示该系统应用于不同机床类型和钻杆尺寸的能力。

This project will create a new product that will automatically improve the surface finish of boring operations in production machine tools. It combines mechanical design for optimising sensor location with advanced modelling to ensure optimal and robust correction values.It builds on the successful Innovate UK project, "Intelligent tool-holding for metal cutting machine tools" where both partners showed the feasibility of predicting the surface roughness of a turned bore when using inputs from a vibration sensor mounted in the tool holder.The innovation in the new project is that we are mounting sensors in the tool holder for deep hole boring on turning operations that will provide feedback for automatic adjustments of machining parameters, as opposed to an experienced operator having to manually adjust during the process. This will lead to improved productivity in the machining process.The main areas of innovation, in order of importance, are:1. To take the advanced surface prediction algorithms and produce corrective models that are robust in manufacturing environments and targeted at improving surface finish.2. To produce a generalised approach to the data acquisition, modelling and feedback to prove that the technology can be used for automatic control with different sized tooling and on different machines.3. To improve the existing state-of-the-art models to allow control based only on data from the tool holder, rather than expensive tool-mounted sensors, which are not commonly available in industry.The project will deliver five demonstrators to show the ability of the system to be applied on different machine tool types and boring bar sizes.