Simulation Technologies for the Development of an Autonomous and Intelligent Machine Tool

2013 ◽  
Vol 7 (1) ◽  
pp. 6-15 ◽  
Author(s):  
Keiichi Shirase ◽  
◽  
Keiichi Nakamoto ◽  
Keyword(s):  
Fault Detection ◽  
Machine Tool ◽  
Cutting Force ◽  
Milling Process ◽  
Planning System ◽  
Cutting Force Prediction ◽  
Intelligent Machine ◽  
Milling Operation ◽  
Digital Copy ◽  
Copy Milling

An autonomous and intelligent machine tool have been developed to solve fundamental issues with the current command method using NC programs, and simulation technologies for its realization have been introduced. The process planning system introduced here, various process plans can be created, and the best process plan can be selected to achieve flexible machining operations in accordance with changes in production planning. Digital Copy Milling, digitizing the principle of copy milling, has opened up new possibilities for machine tool control. The NC machine tool can be directly controlled with the 3D CAD data of the product shape in Digital CopyMilling. Direct machining without the need to create an NC program before milling operation, adaptive control which changes the cutting conditions in accordance with the cutting load during milling operation, and fault detection in the cutting load and avoiding tool breakages can be performed through Digital Copy Milling. Themilling process simulator with integrated milling shape simulator and cutting force simulator provides new functions. Simultaneous cutting force prediction with milling operation provides the possibility of milling process control and fault detection by comparing the measured cutting force with the predicted one.

Development of Innovative Intelligent Machine Tool Based on CAM-CNC Integration Concept – Adaptive Control Based on Predicted Cutting Force –

2019 ◽  
Vol 13 (3) ◽  
pp. 373-381
Author(s):  
Isamu Nishida ◽  
Ryo Tsuyama ◽  
Keiichi Shirase ◽  
Masahiro Onishi ◽  
Katsuyuki Koarashi ◽  
...  
Keyword(s):  
Adaptive Control ◽  
Machine Tool ◽  
Cutting Force ◽  
Real Time ◽  
Machining Efficiency ◽  
Intelligent Machine ◽  
Computer Aided ◽  
Machine Control ◽  
Digital Copy ◽  
Copy Milling

A new methodology to generate instruction commands for prompt machine control as a replacement for the previously prepared numerical control (NC) programs is developed to realize an innovative intelligent machine tool. This machine tool can eliminate NC program preparation, achieve cutting process control, reduce the production lead time, and realize an autonomous distributed factory. In this study, the innovative intelligent machine tool based on the computer-aided manufacturing-computer NC integrated concept is developed. The special feature of this system is to generate instruction commands in real time for prompt machine control instead of using NC programs. Digital Copy Milling, which is a digitized version of traditional copy milling, is realized by using only the computer-aided design model of the product. In this system, the cutting-force simulation is performed simultaneously with the real-time tool path generation. Then, the tool feed rate can be controlled according to the predicted cutting force. Therefore, both the improvement of the machining efficiency and the avoidance of machining problems can be achieved. The instantaneous cutting force model predicts the cutting force. In this system, the work material is represented by the voxel model, and the uncut chip thickness is calculated discretely from the number of voxels removed. Thus, it is possible to predict the cutting force in the case of non-uniform contact between the tool and the work material. In this study, a machining simulation is conducted to validate the proposed method. The results of the simulation show successful tool feed speed adaptation based on the predicted cutting force. The results also show the effective reduction of the machining time. A case study of a custom-made product for dental prosthetics is examined as a good application of both the proposed adaptive control and the Digital Copy Milling system. Through this method, it is possible to improve the machining efficiency and prevent tool breakage.

Development of an Intelligent Stage with Sensor-Less Cutting Force and Torque Monitoring Function

2012 ◽  
Vol 6 (6) ◽  
pp. 736-741 ◽  
Author(s):  
Takafumi Kamigochi ◽  
◽  
Yasuhiro Kakinuma ◽  
Keyword(s):  
Tool Wear ◽  
Machine Tool ◽  
Cutting Force ◽  
Process Monitoring ◽  
Good Condition ◽  
Basic Information ◽  
Monitoring Method ◽  
Intelligent Machine

Intelligent machine tool is required to implement highprecision process monitoring for judging the abnormal tool conditions. Various techniques have been widely researched and studied to maintain machine tool in good condition and to detect tool wear. The occurrence of tool wear can be detected by monitoring the cutting torque, which is basic information for machining. The purpose of this study was to propose a sensor-less cutting force and torque monitoring method and to develop an intelligent stage using this method.

Customized End Milling Operation of Dental Artificial Crown Without CAM Operation

2018 ◽  
Vol 12 (6) ◽  
pp. 947-954 ◽  
Author(s):  
Isamu Nishida ◽  
◽  
Ryo Tsuyama ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Cutting Force ◽  
Real Time ◽  
End Milling ◽  
Feed Speed ◽  
High Productivity ◽  
Nc Program ◽  
Milling Operation ◽  
Machine Control ◽  
Copy Milling ◽  
Tool Motion

A new methodology to generate instruction commands for real-time machine control instead of preparing NC programs is developed under the CAM-CNC integration concept. A machine tool based on this methodology can eliminate NC program preparation, achieve cutting process control, reduce production lead time, and realize an autonomous distributed factory. The special feature of this methodology is the generation of instruction commands in real time for the prompt machine control instead of NC programs. Digital Copy Milling (DCM), which digitalizes copy milling, is realized by referring only to the CAD model of the product. Another special feature of this methodology is the control of the tool motion according to the information predicted by a cutting force simulator. This feature achieves both the improvement in the machining efficiency and the avoidance of machining trouble. In this study, the customized end milling operation of a dental artificial crown is realized as an application using the new methodology mentioned above. In this application, the CAM operation can be eliminated for the NC program generation, and tool breakage can be avoided based on the tool feed speed control from the predicted cutting force. The result shows that the new methodology has good potential to achieve customized manufacturing, and can realize both high productivity and reliable machining operation.

scholarly journals Cutting force prediction for circular end milling process

2013 ◽  
Vol 26 (4) ◽  
pp. 1057-1063 ◽  
Author(s):  
Baohai Wu ◽  
Xue Yan ◽  
Ming Luo ◽  
Ge Gao
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Milling Process ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
End Milling Process

Cutting Force Prediction for Generalized Cornering Milling Process

2011 ◽  
Vol 188 ◽  
pp. 404-409 ◽  
Author(s):  
Xue Yan ◽  
Hua Tao ◽  
D.H. Zhang ◽  
B.H. Wu
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutting Force Prediction ◽  
Geometric Relationship ◽  
The Mathematical Model ◽  
Good Agreement

A developed method to predict the cutting forces in end milling of generalized corners is proposed in this paper. The cornering milling process is divided into a series of cutting segments with different cutting states. The mathematical model of the geometric relationship between cutter and the corner profile is established for each segment. Cutting forces is predicted by introducing the classical cutting force model. The computational results of cutting forces are in good agreement with experimental data.

Real-Time Five-Axis Control Based on Digital Copy Milling Concept to Achieve Autonomous Milling

2008 ◽  
Vol 2 (6) ◽  
pp. 418-424 ◽  
Author(s):  
Keiichi Shirase ◽  
◽  
Keiichi Nakamoto ◽  
Eiji Arai ◽  
Toshimichi Moriwaki ◽  
...  
Keyword(s):  
Real Time ◽  
Movement Control ◽  
3D Models ◽  
Milling Process ◽  
Numerical Control ◽  
Feed Speed ◽  
Tool Paths ◽  
Digital Copy ◽  
Copy Milling ◽  
Five Axis

The Digital Copy Milling (DCM) was proposed to achieve autonomous milling, in which tool paths are generated in real time during milling without requiring Numerical Control (NC) programs. In the DCM, a tracing probe and a master model in conventional copy milling are represented by virtual 3D models, and cutter locations are calculated dynamically based on virtual tracing probe movement in real time. Therefore, not only feed speed, but also radial and axial depths of cut are adapted for milling process control. In addition, new tool paths are added to automatically avoid and recover from cutting troubles. In this paper, an added five-axis tool movement control of DCM demonstrated the effectiveness of the DCM concept.

A Comparison of Two Methods for Geometric Milling Simulation Accelerated by GPU

2012 ◽  
Author(s):  
Masatomo Inui ◽  
Nobuyuki Umezu ◽  
Yuuki Shinozuka
Keyword(s):  
Cutting Force ◽  
Milling Process ◽  
Small Motion ◽  
Milling Simulation ◽  
Milling Operation ◽  
Cutter Path ◽  
Nc Milling ◽  
Depth Buffer ◽  
Swept Volume ◽  
The Cost

For detecting potential problems of a cutter path, cutting force simulation in the NC milling process is necessary prior to actual machining. A milling operation is geometrically equivalent to a Boolean subtraction of the swept volume of a cutter moving along a path from a solid model representing the stock shape. In order to precisely estimate the cutting force, the subtraction operation must be executed for every small motion of the cutter. The performance and the cost of the polygon rendering LSI called GPU are dramatically improved these days. By using GPU, the required time for critical computations in the geometric milling simulation can be drastically reduced. In this paper, the computation speed of two known GPU accelerated milling simulation methods, which are the depth buffer based method and the parallel processing based method with CUDA language, are compared. Computational experiments with complex milling simulations show that the implementation with CUDA is several times faster than the depth buffer based method when the cutter motion in the simulation process is sufficiently small.

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