Designing of Optimal Grinding Cycles, Sustainable to Unstable Mechanical Processing on the Basis of Synthesis of Digital Double Technology, and Dynamic Programming Method

Abstract

Currently, there are non-calculation methods of optimal grinding cycles that are resistant to unstable processing conditions for CNC machines in automated engineering; this makes technologists to lower the cutting conditions significantly to guarantee avoiding reject in grinding operations. As a result, CNC machines are used inefficiently; full automation of the preparation of control programs for CNC machines becomes impossible without using high-performance optimum grinding cycles ensuring stable processing accuracy; it is also impossible to design manufacturing cyber-physical systems in accordance with the concept of “Industry 4.0.” The article describes the synthesis of the digital twin technology and dynamic programming method for designing the optimal grinding cycle for resistance to variable technological factors, which makes it possible to: prevent the rejection of circular grinding; determine the causes of rejection; improve reliability and stability of the grinding cycle to the cumulative effect of variable factors; predict the fluctuation of accuracy and roughness parameters, hardness of the machined surface when processing a batch of parts. The practical result of the synthesis of the digital twin technology and dynamic programming method is an increase in the level of designing automation of control programs for CNC machines, ensuring the calculation of optimal values of radial feed at all cycle stages, the optimal distribution of the allowance removal over the cycle stages, which ensures the minimum main grinding cycle time and reduction in risks to meet the specified requirements on the quality of the machined surface of the part.