Tool replacement and machining optimization for the drill process

该项目特别涉及萨斯卡通日立电力系统加拿大有限公司(以下简称http://www.hitachi.sk.ca/；日立)的钻探过程，该公司是制造各种重型产品(如热交换器)的关键设施。钻削工艺用于在零件上钻出数千个紧公差孔，以生产热交换器。在此过程中，确保所使用的钻头或刀具处于良好状态是至关重要的，因为使用磨损的刀具会导致精度急剧下降，并可能损坏加工工具设备和工件。另一方面，过早更换钻头会增加加工成本。因此，在适当的时候更换刀具，对于改善加工过程的自动化、提高制造生产率和最大限度地降低加工成本具有重要意义。该项目旨在建立一个在线刀具磨损监测系统，并在这些测量的基础上，开发确定需要更换钻头的时间和切割条件的方法，从而在确保孔精度的同时最大化刀具寿命。该项目的成功将立即给日立和其他使用其产品的加拿大行业带来技术和经济上的好处。该项目还将产生制造自动化方面的新知识，同时培训研究生，以满足加拿大制造业对高素质人才日益增长的需求。

This project specifically concerns a drill process at Hitachi Power Systems Canada Ltd., Saskatoon (http://www.hitachi.sk.ca/; hereafter Hitachi), a key facility for the manufacturing of various heavy products, such as heat exchangers. The drill process is used to drill over thousands of tight-tolerance holes on the workpieces for the production of heat exchangers. In the process, it is vital to ensure the drill or cutting tool used is in good condition as the use of worn-out cutting tools leads to a dramatic decline in accuracy, and also potentially damages both the machining tool equipment and the workpiece. On the other hand, replacing drills prematurely adds machining costs. As such, replacing cutting tools at the appropriate time is important for improving the automation of machining processes, increasing manufacturing productivity, and minimizing machining costs. This project aims to establish an on-line tool wear monitoring system and, based on these measurements, develop methods to determine the time when the drills need to be replaced as well as cutting conditions that maximize tool lifetime while ensuring hole accuracy. The success of this project will have immediate technological and economic benefits to Hitachi and other Canadian industries that use their products. The project will also generate new knowledge on manufacturing automation while training graduate students to meet the increasing demand for highly qualified personnel in the Canadian manufacturing sector.