Abstract
The purpose of this study is mainly to develop an information and communication technology (ICT)-based intelligent dimension inspection and tool wear compensation method for precision tuning. With the use of vibration signal processing/characteristics analysis technology combined with ICT, statistical analysis, and diagnosis algorithms, the method can be used to proceed with an on-line dimension inspection and on-machine tool wear auto-compensation for the turning process. Meanwhile, the method can also monitor critical tool life to identify the appropriate time for cutter replacement to reduce machining costs and improve the production efficiency of the turning process. Compared to the traditional ways, the method offers the advantages of requiring less manpower, and having better production efficiency, high tool life, fewer scrap parts, and low costs for inspection instruments. Algorithms and diagnosis threshold values for the detection, cutter wear compensation, and cutter life monitoring were developed. In addition, a bilateral communication module utilizing FANUC Open CNC (computer numerical control) Application Programming Interface (API) Spec was developed for the on-line extraction of instant NC (numerical control) codes for monitoring and transmit commands to CNC controllers for cutter wear compensation. With use of local area networks (LAN) to deliver the detection and correction information, the proposed method was able to remotely control the on-machine monitoring process and upload the machining and inspection data to a remote central platform for further production optimization. The verification experiments were conducted on a turning production line. The results showed that the system provided 93% correction for size inspection and 100% correction for cutter wear compensation.
Highlights
Precision turning plays an important role in manufacturing industry
With the use of the on-line diagnosis method, information and communication technology (ICT), and the empirical statistics method, an on-line monitoring and auto-compensation system for the wear of the turning cutter was developed in this study
ICT, statistical auto‐monitoring/auto‐compensation of tool wear for functions precision of tuning processes
Summary
Precision turning plays an important role in manufacturing industry. The products made by turning process include automotive components, aerospace parts, and precise industrial parts, etc. American Iron and Steel Institute (AISI) H11 steel, and the results showed that M-MGGP has better performance than that of standard MGGP and other methods They proposed a new complexity-based multi-gene genetic programming approach in which the functional relationships between the energy consumption and the input process parameters of a milling process were obtained to find an optimum set of input settings; this will conserve a greater amount of energy from these operations. With the use of the on-line diagnosis method, information and communication technology (ICT), and the empirical statistics method, an on-line monitoring and auto-compensation system for the wear of the turning cutter was developed in this study. The module can save all the monitoring results and information to a remote central computer and send compensation commands to the CNC controller for the predicted tool wear. Turning machine were conducted to verify the feasibility and effectiveness of the proposed system
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