Digital copy milling—autonomous milling process control without an NC program

Abstract

Conventional NC machine tools do not generally allow the change of cutting conditions such as depth of cut and stepover during machining operations, once they are given machining commands as NC programs. For that reason, the NC programs must be prepared adequately and verified in advance, which requires extensive time and effort. It is therefore necessary to develop functions to generate the cutter path autonomously and control the cutting conditions adaptively during machining to optimize the cutting process, maintain stable cutting, and avoid cutting trouble. This paper proposes a new architecture to realize autonomous control of the cutting process without using NC programs. A technique called digital copy milling is developed to control the NC machine tool in real time. The digital copy milling system can generate tool paths in real time, based on the principle of copy milling. In addition, a new control strategy is developed to control the cutting conditions adaptively. A prototype of an autonomous controller was implemented in a three-axis control machining center. Thereafter, experimental milling tests were carried out to verify the effectiveness of the proposed system. The cutter paths were generated autonomously by the digital copy milling system. Results show that the cutting depth and stepover can be changed during milling tests. Cutting conditions were controlled adaptively.