Closed Loop Manufacturing 4.0

该项目提出了一种基于物理模拟模型、在线**监控和符合Industry 4.0原则的实时过程控制的闭环制造过程。加工过程**将在物理生产之前的虚拟环境中进行模拟，并存储在云中或**数据库中。实时加工信息，如切削力和振动，将从固有的**计算机数控系统数据中获得。预先模拟的结果和实时测量将**用于调整加工条件，以抑制颤振，防止刀具过度磨损，避免机器过载，同时最大限度地减少生产周期时间。因此，将开发一个**数字双加工系统(即模拟和实时相结合)，具有**模拟、监控和自我优化的核心功能。**该项目的具体目标包括：(1)利用主轴电流识别刀尖动力学以避免颤振；(2)利用进给驱动电流在线监测刀具磨损；(3)轨迹规划和进给速度**优化以提高生产率；(4)识别进给驱动动力学以监控切削力；**和(5)将算法集成到商业可行的加工模拟和监控**软件中。**项目结果将用于通过增强智能**加工功能来减少加工时间和零件废品率。将开发和应用一种商业产品，用于大批量生产，以及**用于小批量和高度定制类型的部件。该项目预计将惠及航空航天、汽车、工业机械和生物医疗设备等关键制造业。

This project proposes a Closed Loop Manufacturing process with physics-based simulation models, online**monitoring, and real-time process control in accordance with Industry 4.0 principles. The machining process**will be simulated in a virtual environment ahead of physical production and stored in the cloud or in a**database. Real-time machining information, such as cutting force and vibration, will be obtained from inherent**CNC (Computer Numerical Control) system data. The pre-simulated result and real-time measurement will be**used in conjunction to adjust the machining conditions for suppressing chatter vibrations, preventing excessive**tool wear, and avoiding machine overloads, while minimizing the production cycle time. As a result, a**so-called digital twin machining system (i.e. combination of simulation and real-time) will be developed with**core functionalities in simulation, monitoring, and self-optimization.**Specific aims of this project include: (1) Identification of tool tip dynamics using spindle current for chatter**avoidance; (2) Online tool wear monitoring using the feed drive current; (3) Trajectory planning and feedrate**optimization for productivity increase; (4) Identification of feed drive dynamics for cutting force monitoring;**and (5) Integration of the algorithms into a commercially viable machining simulation and monitoring**software.**The project results will be used to reduce machining time and part scrap rates by enhancing intelligent**machining feature. A commercial product will be developed and applied for high volume production, as well as**for low volume and highly customized type of parts. The project is expected to benefit key manufacturing**sectors such as aerospace, automotive, industrial machinery, and biomedical devices.