Abstract
Abstract. The article presents methodology for designing optimal feed control cycles resistant to unstable machining conditions for a batch of parts in round grinding operations performed on CNC machines. To improve the quality and reliability of control programs for CNC machines, a digital twin (DT) is proposed to be used. It performs virtual testing of a given grinding cycle for the possibility of defect occurrence at some combination of variable technological factors. To design the optimal grinding cycle by calculating the optimum trajectory of the radial feed change cycle, we propose the dynamic programming method (DPM) used in solving the classical transport problem, in which a network of roads with intermediate stations is specified. In the task it is necessary to find the optimal trajectory of transport. The conditions for the appearance of defects detected by the DT are introduced into the system of restrictions, and the feed cycle is again optimized in the DPM optimization system. A new optimized cycle is again tested by the DT. These iterations are repeated until the DT fixes the present of a defect for the operation. The methodology proposed in the article for the synthesis of digital twin and DPM technologies at the stage of preparation of control programs for CNC machines makes it possible to guarantee the maximum productivity of the grinding operation while ensuring the specified quality of the machined surface under varying processing conditions that vary within the specified limits.
Highlights
To perform grinding operation, all you need is a control program, which manages the execution of user program to prevent errors and cutting parameters of the automatic steps cycle in CNC programming radial feed
The developed methodology for the design of automatic grinding cycles with optimal parameters of cutting conditions for CNC machines allows to ensure the stable quality of the surface to be processed in terms of accuracy, roughness and hardness, under varying conditions for processing a batch of parts
– removal allowance model based on the relationship of the elastic deformations of the technological system with the parameters of cutting conditions and processing conditions;
Summary
All you need is a control program, which manages the execution of user program to prevent errors and cutting parameters of the automatic steps cycle in CNC programming radial feed. Within the framework of this concept, a system model DT was designed for: (1) Preventing the defect and the causes of its occurrence in the operation of round grinding; (2) Increasing the reliability and stability of grinding cycle to the combined effect of variable factors; (3) Providing full automation of the design of the control program at the stage of calculation and programming of cutting parameters; (4) Forecasting fluctuations in accuracy, roughness, hardness of the machined surface after machining a batch of parts; (5) Fixing an array of variable factors which caused defects; (6) Forming the array of restrictions of the objective function with variable grinding conditions for the cycle optimization system; (7) Automatic transfer of the array of the objective function restrictions according to the changing grinding conditions in the cycle optimization system; (8) Automatic loading of the tested cycle into the diagnostic system; (9) Automatic completion of grinding cycle diagnostics. We have developed a system for designing optimal cycles with improved reliability and resistance to variable grinding conditions
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