Development of a CAM-in-the-Loop System for Cutting Parameter Optimization using an Instrumented Tool Holder

Abstract

This paper presents a methodology for cutting parameter optimization based on integrating a Computer-Aided Manufacturing (CAM) system and an instrumented tool holder capable of identifying unstable process conditions during milling. Compared to state-of-the-art adaptive process control systems with feed rate and spindle speed override modification, the presented approach utilizes high-level CAM objects in the data loop, thus, provides opportunities for automatic adaption of the original machining strategy and various cutting parameters. Based on the presented CAM-in-the-loop approach, the system uses sensor feedback while producing the first piece to optimize the CAM planning parameters for all subsequent units of a specific production order. The approach is demonstrated using milling use-cases manufactured on a machining center with an instrumented tool holder for process vibration measurements.