GB2462117A - Controlling a machine tool - Google Patents
Controlling a machine tool Download PDFInfo
- Publication number
- GB2462117A GB2462117A GB0813627A GB0813627A GB2462117A GB 2462117 A GB2462117 A GB 2462117A GB 0813627 A GB0813627 A GB 0813627A GB 0813627 A GB0813627 A GB 0813627A GB 2462117 A GB2462117 A GB 2462117A
- Authority
- GB
- United Kingdom
- Prior art keywords
- cutting
- tooth
- tool
- component
- characteristic signature
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 238000005520 cutting process Methods 0.000 claims description 78
- 238000000034 method Methods 0.000 claims description 42
- 230000008569 process Effects 0.000 claims description 22
- 238000012544 monitoring process Methods 0.000 claims description 16
- 230000007547 defect Effects 0.000 claims description 8
- 230000004044 response Effects 0.000 claims description 4
- 238000012545 processing Methods 0.000 claims description 2
- 238000005070 sampling Methods 0.000 claims description 2
- 239000000463 material Substances 0.000 abstract description 13
- 230000002547 anomalous effect Effects 0.000 abstract description 11
- 230000005856 abnormality Effects 0.000 abstract description 5
- 238000003801 milling Methods 0.000 abstract description 5
- 238000003754 machining Methods 0.000 description 18
- 238000004458 analytical method Methods 0.000 description 5
- 238000009826 distribution Methods 0.000 description 3
- 230000014509 gene expression Effects 0.000 description 3
- 230000007257 malfunction Effects 0.000 description 3
- 230000036346 tooth eruption Effects 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000004364 calculation method Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
Classifications
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/404—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/406—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by monitoring or safety
- G05B19/4065—Monitoring tool breakage, life or condition
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/37—Measurements
- G05B2219/37233—Breakage, wear of rotating tool with multident saw, mill, drill
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/37—Measurements
- G05B2219/37247—By electrical contact, disappears when breakage
Landscapes
- Engineering & Computer Science (AREA)
- Human Computer Interaction (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Machine Tool Sensing Apparatuses (AREA)
Abstract
A machine tool 10 e.g. a milling cutter, has a number of teeth T1 ,T2 to cut a surface 12 of a component 10. If any of the teeth T1,T2 become damaged, the damaged tooth T1,T2 will produce a surface abnormality whilst in contact with the surface 12 of the component 10. In order to reduce the surface abnormalities caused by a damaged tooth the contact time of each tooth T1,T2 is controlled in real-time. Data is analysed for any evidence of an anomalous event and if one is detected the tooth that actually created the anomaly is classified as damaged and its corresponding length of cut L, is instantaneously reduced. By individually adjusting L the system can prevent material being feed to the damaged tooth and reduce the number of surface anomalies that might appear.
Description
METHOD AND APPARATUS FOR CONTROLLING A MACHINE TOOL
The present invention relates to a method and apparatus for controlling a machine tool in the event that the tool is damaged or a surface defect is detected. In particular it relates to the control of a cutting tool when one of cutting teeth is damaged.
Cutting tools having multiple teeth are used in the manufacture of components. However if just one of the cutting teeth becomes damaged or breaks during a machining operation extensive damage can occur on the surface being machined resulting in either the component being scrapped or extensive reworking. If the tool continues to be used with a broken or damaged tooth then this will also have a negative effect on the remaining teeth. The rest of the teeth become overloaded and the tool is unbalanced which leads to tool malfunctions. Tool malfunctions ultimately lead to the generation of even more surface abnormalities that will require correction by reworking the component.
It is known to monitor the machining process and if a tool malfunction is detected, stop machining and change the damaged tool. Tool damage can be sensed in a variety of ways by detecting changes in vibration, cutting forces and acoustic emission signals. The process may be monitored automatically or require operator intervention.
The present invention seeks to provide an improved method and apparatus for controlling a machine tool when tool damage or surface defects are detected.
According to the present invention a method of controlling a machine tool for cutting the surface of a component, the cutting tool having a least one tooth which cuts the surface for a predefined cutting length comprises the steps of monitoring at least one process parameter, processing the process parameter to produce a new characteristic signature, comparing the new characteristic signature to at least one stored characteristic signature to produce an output signal indicative of whether a tooth is damaged or a defect is present on the surface of the component and adjusting the cutting length of an individual tooth in response to an output signal that indicates that either the tooth is damaged or a surface defect is present.
In the preferred embodiment of the present invention the cutting length of each tooth is adjusted by controlling the contact time between the tooth and the surface of the component.
The cutting length of each tooth may be adjusted by changing the rate at which the cutting tool is fed across the surface of the component or by changing the feed rate of the component.
The process parameter that is monitored may be an acoustic emission signal.
Preferably a number of characteristic signatures are stored for comparison with the new characteristic signature and the stored characteristic signals may be from preceding cutting operations.
In the preferred embodiment of the present invention the stored characteristic signals are produced by monitoring both the acoustic emission signals and the cutting force.
The cutting length of each tooth is adjusted between a predefined maximum and minimum and these are calculated using the effective cutting diameter of the tool. The effective cutting diameter of the tool takes into account the angle of the cutting edge and the amount of wear.
A further aspect of the present invention is directed to an apparatus for controlling a machine tool. The apparatus includes a plurality of sensors for monitoring machine parameters, means for sampling the sensor outputs, means for producing a characteristic signature from the sensor outputs, means for storing a multiplicity of characteristic signature and means for comparing a new characteristic signature with the stored characteristic signature, means to provide an output signal in accordance with the result of the comparison and means for adjusting the cutting length of individual teeth of the cutting tool in response to the output signal.
The invention will now be described with reference to the accompanying drawings in which: Figures la-id show the signals from an on-line process monitoring system in accordance with the present invention.
Figure 2 is a flow chart showing the dataflow for a tool monitoring and control system in accordance with the present invention.
Figures 3a-3c are schematic representations of a cutting strategy in accordance with the present invention for avoiding surface anomalies.
Figures 4a and 4b show the cutting forces on individual teeth.
Milling is a metal cutting process in which a multi-edged tool is rotated whilst being continuously fed across a component. When each individual tooth is in contact with the surface of the component it removes material and has an associated length of cut Ls. If any of the teeth become damaged, the damaged tooth will produce a surface abnormality whilst in contact with the surface of the component. In order to reduce the surface abnormalities caused by a damaged tooth the contact time of each tooth is controlled in real-time. Similarly if the surface of a component has a surface defect the contact time of each tooth can be adjusted in real-time.
The control of the contact time of each tooth in real time is achieved by process monitoring the machining of the component. Signal analysis is used to predict the required surface integrity and this is used as feedback to a control system that acts in real time to analyse the tool path and optimise the tool path based on the feedback from the process monitoring.
The signal analysis methodologies used must correctly identify anomalies on the surface of the component, gauge the occurrence of the surface anomalies and establish the signal patterns for the various anomalous and non-anomalous states of the cutting process.
To achieve this process parameters are monitored and processed to produce a characteristic signature indicative of the various anomalous and non-anomalous states of the cutting process.
In the preferred embodiment of the present invention the process parameters that are monitored are cutting force and acoustic emission data. Signal analysis of the cutting force is synchronised with acoustic emission data to provide information on the surface integrity of the component being machined.
Referring to figure 3a a machining tool 10, is a milling cutter and has two teeth Ti and T2 which are used to cut material at the surface i2 of a component 14. One of the teeth T2 is damaged and has a rounded cutting edge 15.
The other tooth Ti is undamaged and material is fed to it for cutting.
Figure id shows a metallographic inspection of the surface 12 after machining. Anomalies 16 can clearly be seen on the machined surface 12 at spaced intervals, see for example zone 2 of figure id. The anomaly 16 is in the form of a folded lap. The folded lap occurs when excess material is not removed by the damaged tooth T2 but is folded over by the rounded edge 15. In between these anomalies are "healthy" regions, zone 1 in figure id, were the undamaged tooth Ti has removed material from the surface 12 of the component 14.
The cutting forces and the acoustic emission signals corresponding to zones 1 and 2 are shown in figures la and lb respectively. Figure ic shows a time-frequency representation of the acoustic-emission signal.
In zone 2 the amplitude of the acoustic emission signal and the cutting force are reduced when compared to zone 1. The damaged tooth T2 has a rounded cutting edge 15 and a slightly smaller cutting radius than the undamaged tooth Ti and thus the damaged tooth T2 removes less material from the surface 12 of the component 14. This leads to the corresponding reduction in the amplitudes of the cutting force and the acoustic emission for the damaged tooth T2 compared to the healthy tooth Ti.
The two different types of cutting by the teeth Ti and T2 have a direct influence on the time-frequency component of the acoustic emission signals. For example the time frequency component labelled TF1 in figure ic is present in zone 1 but not in zone 2. Similarly the time-frequency component TF2 is not present in zone 1 but is present in zone 2.
Having identified anomalous (zone 2) and non-anomalous (zone 1) states of the cutting process these are then calibrated against the sensorial signals of cutting force and acoustic emission to produce characteristic signatures.
A database with an extensive number of characteristic signatures for anomalous events is thus established. The signatures from a combination of cutting force and acoustic emission are then used in an on-line process monitoring system which inputs to a control system to optimise the tool path and reduce the number of surface anomalies during milling or any other machining process.
Initially both the cutting force and the acoustic emission signal are monitored and compared to produce a signature which is characteristic of the anomalous (zone 2) and no-anomalous (zone 1) parts of the process. These characteristic signatures are stored for comparison with any subsequently produced new signatures.
The control system operates in real time and consists of a tool path analyser and an on-line tool path optimiser.
The tool path analyser divides the tool path into small steps according to the tool speeds and feeds. The tool path optimiser is based on the feedback provided by the process monitoring system.
The tool path analyser operates by extracting the length of the tool path from the computer code controlling the cutter 10. The length of the tool path is extracted prior to machining and is divided into smaller computer controlled steps. For each step a supervision window is defined, equivalent to zone 1 and zone 2 in figure 1 and each has an associated length of cut L. The supervision windows aim to monitor the condition of the surface 12 of the component 14 associated with the length of cut L. Individual teeth Ti and T2 have individual lengths of cut L and an associated supervision window.
At the end of each supervision window the signals are analysed and the health of the machining process is decided for each individual tooth. For each step the process monitoring system will extract the sensorial data, such as cutting force and acoustic emission and analyse the cutting signals.
After the tool path has been divided into smaller steps and the cutting parameters analysed, machining is carried out using the on-line tool path optimiser so that surface anomalies can be avoided.
The on-line tool path optimiser uses an algorithm which takes into account a number of machining parameters and controls the length of cut L. If the angular distance between the teeth is the same the maximum and minimum length of cut allowed are given by the expressions; L m x = = Vf XXDe xDexn (1) s a Z z xV xl000 1000 n C VxD I L = f e 12xap (2) smin z xV x1000 D 11 C e where V0 is the cutting speed, Vf is the feed speed, Z, is the number of teeth, ap is the depth of cut, F is the feed per tooth relative to De, De is the effective cutting diameter and is defined by the expression: 2 x ap DeDc+ -VB (3,) tan K where D0 is the cutting tool diameter, ap is the cutting depth and i is the major cutting edge angle and VB is the mean tool flank wear level.
Lsmax represents an improved expression of the programmed feed per tooth that includes an effective cutting diameter. However if Lsmax is very small, close to zero but not actually zero, then a rubbing effect appears.
To avoid this L must be kept above L111,.
In constructing the algorithm the following policy must be applied: should not be bigger than Lsrrax and the chosen value for L must be between them for cutting to occur.
The mean level of tool flank wear (VB) must not be bigger than 0.3mm and should always be updated using a prediction model gauged with measurements.
As seen in equation (3) De is dependant on the major cutting edge angle and the mean tool wear level. Using De instead of D in the calculations for the maximum and minimum step length forces the system to be dependant on the mean tool wear level.
A flow chart showing the dataflow of the entire system is shown in figure 2.
Prior to machining a rectified computer file is generated to control the machining process. The rectified file is based on the original and contains details of each individual machining step. A decision is made according to cutting parameters if active control is possible or not. If "yes" machining continues and the sensorial signals of cutting force and acoustic emission are continuously monitored and logged by the process monitoring system described previously.
The data is analysed for any evidence of an anomalous event. If one is detected the tooth that actually created the anomaly is classified as damaged and the corresponding length of cut L is instantaneously reduced to zero.
Machining is continued until the end of the tool pass.
By individually adjusting L, the system can actually prevent material being fed to the damaged tooth T2 and thus dramatically reduces the number of surface anomalies that might appear. This adjustment is performed whilst at the same time the normal amount of material is fed to the cutting edge of the undamaged tooth Ti. A schematic of this procedure is presented in figures 3a-3c.
If tooth Ti is classified as healthy by the process monitoring system the material is fed to it according to the initial cutting parameters in the original computer generated model. The healthy tooth Ti is represented in figure 3a.
While the cutting process continues sensorial data is montitored and processed to produce a new characteristic signature which is compared to the previously stored data.
At the end of the cut a decision is taken on how the tooth will be marked for the next cutting operation. If Ti is marked again as healthy then the next cut proceeds as in figure 3c.
If however a tooth is marked as damaged then no material is fed to it. There is then no contact between the cutting edge of the tooth and the surface of the component i4, as for T2 is figure 3b.
Whilst initially both the cutting force and the acoustic emission signal are monitored and compared to produce the stored signatures which are characteristic of the anomalous (zone 2) and no-anomalous (zone i) parts of the process subsequently data from just one of the process parameters is actually required. This offers the advantage that for subsequent process monitoring just the acoustic emission signal can be used for comparison purposes. This avoids the need to use force sensors (dynamometers), which are difficult to fit, within an industrial manufacturing unit.
In another embodiment if a considerable difference in cutting force is detected between individual teeth, figure 4a, then this can be compensated for by adjusting L to a specific value between Lsmax and By continuously adjusting L the cutting force signals for individual teeth can have similar amplitudes, figure 4b. This prolongs the life of the individual teeth by avoiding an uneven distribution in the cutting forces and helps to control the thickness of the chips of material that are removed from the surface of the component 14 during the machining operation. Adjusting L to maintain an even distribution of the cutting forces is also advantageous when using fixtures to hold the work pieces.
Whilst the present invention has been described with reference to a milling tool it will be appreciated by one skilled in the art that it is equally applicable to any machining operation in which the surface of a component is cut by one or more teeth. The method is independent of the number of cutting teeth and supports the implementation of a tool wear model that is updated at the end of each tool pass. By individually adjusting the length of cut L a control system in accordance with the present invention offers the advantage that the system can avoid feeding material to a damaged or faulty tooth and thus dramatically reduces the number of surface anomalies. The method therefore helps to maintain a desired surface finish and improves productivity by reducing the reworking time.
Tooling life is enhanced by the maintenance of an even cutting force distribution and loads experienced by any fixtures holding the component are more evenly distributed.
A control system in accordance with the present invention can also be used to adjust the cutting length of an individual tooth in the event that a defect is detected on the surface of the component. If one of the process parameters monitored is an acoustic emission signal then this can be used to detect surface anomalies. If a surface anomaly is present on the component then the control system operates to adjust the cutting length to compensate for the anomaly.
Claims (14)
- Claims: 1. A method of controlling a machine tool for cutting the surface of a component, the cutting tool having a least one tooth which cuts the surface for a predefined cutting length comprising the steps of; monitoring at least one process parameter, processing the process parameter to produce a new characteristic signature, comparing the new characteristic signature to at least one stored characteristic signature to produce an output signal indicative of whether a tooth is damaged or a surface defect is present, adjusting the cutting length of an individual tooth in response to an output signal that indicates that the tooth is damaged or a surface defect is present.
- 2. A method as claimed in claim 1 in which cutting length of each tooth is adjusted by controlled the contact time between the tooth and the surface of the component.
- 3. A method as claimed in claim 1 or claim 2 in which the cutting length is adjusted by changing the rate at which the cutting tool is fed across the surface of the component.
- 4. A method as claimed in claim 1 or claim 2 in which the cutting length is adjusted by changing the feed rate of the component.
- 5. A method as claimed in any preceding claim in which the monitored process parameter is an acoustic emission signal.
- 6. A method as claimed in any preceding claim in which a number of characteristic signatures are stored for comparison with the new characteristic signature.
- 7. A method as claimed in any preceding claim in which the characteristic signals from preceding cutting operations are stored for comparison with the new characteristic signature.
- 8. A method as claimed in claim 6 or claim 7 in which the stored characteristic signal is produced by monitoring the cutting force and an acoustic emission signal.
- 9. A method as claimed in any of claims 1-8 in which the cutting length of each tooth is adjusted between a predefined maximum and minimum.
- 10. A method as claimed in claim 9 in which the defined maximum and minimum lengths of cut are calculated using the effective cutting diameter of the tool which takes into account the angle of the cutting edge and the amount of wear.
- 11. Apparatus for controlling a machine tool adapted and arranged to operate in accordance with a method as claimed in any of claims 1-10.
- 12. Apparatus as claimed in claim 11 comprising a plurality of sensors for monitoring machine parameters, means for sampling the sensor outputs, means for producing a characteristic signature from the sensor outputs, means for storing a multiplicity of characteristic signature and means for comparing a new characteristic signature with the stored characteristic signature, means to provide an output signal in accordance with the result of the comparison and means for adjusting the cutting length of individual teeth of the cutting tool in response to the output signal.
- 13. A method as hereinbefore described with reference and as shown in figures 1-4.
- 14. An apparatus as hereinbefore described with reference to and as shown in figures 1-4.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0813627A GB2462117A (en) | 2008-07-25 | 2008-07-25 | Controlling a machine tool |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0813627A GB2462117A (en) | 2008-07-25 | 2008-07-25 | Controlling a machine tool |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB0813627D0 GB0813627D0 (en) | 2008-09-03 |
| GB2462117A true GB2462117A (en) | 2010-01-27 |
Family
ID=39746916
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB0813627A Withdrawn GB2462117A (en) | 2008-07-25 | 2008-07-25 | Controlling a machine tool |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2462117A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105388842A (en) * | 2015-12-10 | 2016-03-09 | 华中科技大学 | Part surface machining defect positioning method |
| CN107203183A (en) * | 2016-03-17 | 2017-09-26 | 发那科株式会社 | The operation management method of lathe |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4249243A (en) * | 1977-02-11 | 1981-02-03 | Toshiba Kikai Kabushiki Kaisha | Automatic operating systems of machine tools and method |
| US4564910A (en) * | 1983-04-25 | 1986-01-14 | Eaton Corporation | Method and algorithms therefore for monitoring the performance of a tool and modifying the feed rate thereof |
| US4709198A (en) * | 1985-05-29 | 1987-11-24 | Kabushiki Kaisha Toyota Chuo Kenkyusho | High-speed machining controller |
-
2008
- 2008-07-25 GB GB0813627A patent/GB2462117A/en not_active Withdrawn
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4249243A (en) * | 1977-02-11 | 1981-02-03 | Toshiba Kikai Kabushiki Kaisha | Automatic operating systems of machine tools and method |
| US4564910A (en) * | 1983-04-25 | 1986-01-14 | Eaton Corporation | Method and algorithms therefore for monitoring the performance of a tool and modifying the feed rate thereof |
| US4709198A (en) * | 1985-05-29 | 1987-11-24 | Kabushiki Kaisha Toyota Chuo Kenkyusho | High-speed machining controller |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105388842A (en) * | 2015-12-10 | 2016-03-09 | 华中科技大学 | Part surface machining defect positioning method |
| CN107203183A (en) * | 2016-03-17 | 2017-09-26 | 发那科株式会社 | The operation management method of lathe |
| CN107203183B (en) * | 2016-03-17 | 2020-04-03 | 发那科株式会社 | Method for managing operation of machine tool |
Also Published As
| Publication number | Publication date |
|---|---|
| GB0813627D0 (en) | 2008-09-03 |
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| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |