Development of smart machining system for optimizing feedrates to minimize machining time

Abstract

Feedrate optimization is an important aspect of getting shorter machining time and increase the potential of efficient machining. This paper presents an autonomous machining system and optimization strategies to predict and improve the performance of milling operations. The machining process was simulated and analyzed in virtual machining framework to extract cutter-workpiece engagement conditions. Cutting force along the cutting segmentation is evaluated based on the laws of mechanics of milling. In simulation, constraint-based optimization scheme was used to maximize the cutting force by calculating acceptable feedrate levels as the optimizing strategy. The intelligent algorithm was integrated into autonomous machining system to modify NC program to accommodate these new feedrates values. The experiment using optimized NC file which generates by our smart machining system were conducted. The result showed autonomous machining system, was effectively reduced 26%. Highlights The smart machining system was implemented in the CNC machine. Optimal feed rates enhance machine tool efficiency. The smart machining system is reliable to reduce machine time.

A Low-Cost Vision-Based Monitoring of Computer Numerical Control (CNC) Machine Tools for Small and Medium-Sized Enterprises (SMEs)

“…Today, computer numerical control (CNC) machine tools, one of widely used processing equipment on the shop floor, transform the raw material into a complete part, which has free-from or sculptured surfaces, needed to make a product with a numerical control (NC) part program [24]. Conventionally, while setting up and running a machine tool on a machining shop floor, operators can monitor operational data via a specific human machine interface (HMI) of the machine tool and are responsible for checking an operational status and changing work pieces after machining a part [25].…”

Feedrate optimization for 2.5D milling operations

“…Key functional block of force based feedrate scheduling procedure is module for prediction of milling forces. Model for instantaneous milling forces based on mechanistic approach with simulation of one revolution of the discretized tool [2][3][4][5] was used in this paper.…”

“…On the other hand, in many research centers, significant results were achieved in development of the models for optimization of the feedrate, based on different goal functions [2][3][4]. Most of them use maintaining the predefined level of the cutting force as an optimization criterion, regarding the great importance of cutting forces on machining effects.…”

“…Successful results of integration of workpiece model, cutting force model and set of specific routines for processing of the workpiece model and NC-code, in order to perform feedrate optimization for milling operations, was reported in number of papers [2][3][4][5]17, [20,21].…”

Increasing the Productivity of Multitool Machining on Automated Lathes by Optimizing the Machining Plan

“…For examples, approaches to optimization have been proposed for multiaxial machining [3]; milling [4,5]; the tool trajectory in CNC machines [6]; the cutting speed (on the basis of the shear-plane model in chip formation) [7]; cutting processes with tool wear and change in the cutting force in turning [8]; production time, product cost, and product quality [9]; the cutting conditions in turning so as to minimize energy consumption [10]; and automatic grinding cycles [11].…”