Abstract
In numerical control (NC)-based machining, NC data-based tool paths affect both quality and productivity. NC data are generated according to cutting conditions. However, NC data causing excessive cutting load can accelerate tool wear and even result in tool damage. In the opposite case, increasing machining time can affect productivity. NC data can influence surface quality from the perspective of cutting dynamics according to machine tool–material–tool combination. There have been a lot of studies on tool-path optimization. However, it is impossible to perfectly predict cutting dynamics such as tool wear, material non-uniformity, chatter, and spindle deformation. In fact, such prediction-based tool-path optimization can cause errors. Therefore, this study attempts to synchronize spindle load and NC data and uniformize the machining load through the analysis of stored data using digital-twin technology, which stores and manages machining history. Uniformizing machining load can reduce rapid traverse in the event of no load, feed rate in an overload area, and shock on a tool when the tool and material are met by adding approach feed. Analyzing results of the attempts proposed in this paper, the chatter was completely removed in the machining with D100 and D16, although some chatter remained in the machining with D25 and D16R3 tools. In addition, the processing time could be reduced from a minimum of 7% to a maximum of 50% after optimization.
Highlights
Accepted: 31 March 2021In general, in the event of a chatter, severe vibration is found for tools and workpieces, causing diverse damages such as quality deterioration, decrease in tool lifespan, and machine damage with a chatter mark on the surface
Software has evolved, numerical control (NC) codes are generated based on predictions
The no-load section, and the chatter occurrence section can be identified through the initial processing of the part, optimized NC code can be generated by storing and analyzing related data
Summary
In the event of a chatter, severe vibration is found for tools and workpieces, causing diverse damages such as quality deterioration, decrease in tool lifespan, and machine damage with a chatter mark on the surface. Previous studies have performed chatter detection based on diverse signals such as signal measurement using a tool dynamometer [2,3], and analysis of sound-pressure signals with a microphone [4]. Information on changes in machining environments (e.g., materials, tools, cutting conditions, acceleration/deceleration, supplementary axis) is necessary [1,7]. These methods have some difficulties in actual application. Have been considerably improved [10,11,12,13,14] This method cannot perfectly predict cutting dynamics such as tool wear, material non-uniformity, chatter vibration, and spindle deformation during machining. Effects are minor in mass-production or automotive parts in which products with the same shape are being processed consecutively
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