Thermal compensation

strategy for CNC lathes

Industrial partner
 Objective of the Project

To develop an algorithm and electronics specific to

CNC lathes to enable thermal compensation at the tool point

Advanced Manufacturing Technology Development Centre 2

S No Tasks Deadline Status
1 Validation of existing Prediction Models 11-06-2019 To be completed by
15-06-2019
2 Validation of Compensation methodology 11-06-2019 Completed
3 Testing the efficiency of AHU in presence of machine 15-06-2019 On Process
running
4 Experimentation 28-06-2019 Yet to be Started

Advanced Manufacturing Technology Development Centre 3

Objective:
Determining the accuracy of models with existing data

Validation of existing Prediction Models: (Deadline: 15-06-2019- On Process)

- Only Considering Temperature

- Temperature along with Temperature history
- Temperature, Temperature history along with Spindle drift history
- Temperature, Temperature history, Spindle drift history & Actual value
compensation at every 10th cycle
- Clustering & Non-clustering approach comparison

Advanced Manufacturing Technology Development Centre 4

 Experiment to validate Compensation Methodology - Completed
Experiment with the virtual cycle was conducted by giving Manual
Compensation for each cycle

Cutting Cycle Parameters with Coolant (Virtual cycle with axis movement):

Cutting Cycle Parameters with Coolant

No. of passes Surface Speed

Operation DOC (mm) Feed (mm/rev) (m/min)

Roughing 0.25 0.5 6 400

Cutting Length –
35 mm
Semi
0.125 0.3 3 400
Finishing
Finishing 0.125 0.15 1 400

Advanced Manufacturing Technology Development Centre 5

Objective:
Finalisation of rates of cooling and heating cycles (rate-1 & rate-2)

Testing the efficiency of AHU in presence of machine running:

Deadline: 15-06-2019 – On Process:

- Cooling efficiency of AHU for every 2°C & 5 °C from 30 to 20°C

From 30 to 28, 28 to 26, 26 to 24, 24 to 22, and 22 to 20°C respectively.

- Heating efficiency of AHU for every 2°C & 5 °C from 20 to 30°C

From 20 to 22, 22 to 24, 24 to 26, 26 to 28, and 28 to 20°C respectively.

Advanced Manufacturing Technology Development Centre 6

Experiments to be conducted: (Deadline: 28-06-2019)

- Cooling cycle of Machine from 30°C at rate-1

- Cooling cycle of Machine from 30°C at rate-2

- Heating cycle of Machine from 20°C at rate-1

- Heating cycle of Machine from 20°C at rate-2

- Intermittent stoppage trials

Cycle: 9 hours including one hour lunch break stoppage

for heating & cooling cycle.

Advanced Manufacturing Technology Development Centre 7

Tentative experimental schedule:
S No Date Experiment Title
1 17-06-2019 Cooling cycle of Machine from 30°C at rate-1
2 18-06-2019 Cooling cycle of Machine from 30°C at rate-2
3 20-06-2019 Heating cycle of Machine from 20°C at rate-1
4 22-06-2019 Heating cycle of Machine from 20°C at rate-2
5 24-06-2019 Intermittent stoppage trials -1
6 25-06-2019 Intermittent stoppage trials -2

Cutting Cycle Parameters with Coolant (Virtual cycle with axis movement):
Cutting Cycle Parameters with Coolant
No. of passes
Surface Speed
Operation DOC (mm) Feed (mm/rev) (m/min)

Roughing 0.25 0.5 6 400

Cutting Length –
Semi
35 mm
0.125 0.3 3 400
Finishing
Finishing 0.125 0.15 1 400

Advanced Manufacturing Technology Development Centre 8

 List of activities performed:
S No Date Experiment Title Objective Results

1 24-05-2019 Trial1- with AC Trial On Process

2 25-05-2019 Trial1- without AC Trial On Process

3 06-06-2019 Exp1 - Open Ambient - Without Compensation Variation under same On Process
condition on the next day On Process
4 07-06-2019 Exp2 - Open Ambient - Without Compensation
5 10-06-2019 Exp3 - Open Ambient - Without Compensation On Process
6 11-06-2019 Exp4 – With Compensation Trial Trial On Process
Validation – Manual
7 12-06-2019 Exp5 – With Compensation – Full Day On Process
Compensation

Cutting Cycle Parameters with Coolant (Virtual cycle with axis movement):
Cutting Cycle Parameters with Coolant
No. of passes
Surface Speed
Operation DOC (mm) Feed (mm/rev) (m/min)

Roughing 0.25 0.5 6 400

Cutting Length –
Semi
35 mm
0.125 0.3 3 400
Finishing
Finishing 0.125 0.15 1 400

Advanced Manufacturing Technology Development Centre 9