Integration of Discrete Machining Models

into an Open-Architecture Machine Tool Controller

Robert B. Jerard Barry K. Fussell
University of New Hampshire
http://www.unh.edu/dml

Project Goals
• Cutting Condition Optimization
• Improved Productivity of NC
Machining
• “Smarter”NC Machine Tools
– Geometric and Mechanistic
Cutting Models MDSI Open Architecture Controller
retrofit on a FADAL VMC
– Sensor Rich Design and Manufacturing Lab -
University of New Hampshire
• Develop “on-line” Model Calibration
 Example: Finish Machining of Bottle Mold
Large
variations in
Peak Forces reduced by 70% cusp height
(vs 30 ipm constant feedrate) create
uneven
forces for
Cutting time reduced by 74% finish
machining
(vs 7 ipm constant feedrate)

Force Peak Cutting Forces versus Tool Position

(lbf)
80
70
30 ipm - cut time = 61 minutes
60 7 ipm - cut time = 216 minutes
50
40 Optimized - cut time = 53 minutes
30
Computer time required
20
to optimize = 9 min.
10 (pentium II 400 Mhz)
0
0 5000 10000 15000 20000 25000
Tool Move Number