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Intelligent Machining & Process Control :

Cost optimization in machining Tool wear monitoring Practical tool wear metrology Continuous optimization Process stability monitoring Acoustic and vibration monitoring LabVIEW based signal processing. Intelligent Machining & Process Control :. Team: .

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Intelligent Machining & Process Control :

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  1. Cost optimization in machining Tool wear monitoring Practical tool wear metrology Continuous optimization Process stability monitoring Acoustic and vibration monitoring LabVIEW based signal processing Intelligent Machining & Process Control :

  2. Team: Sponsor: General Dynamics - OTS Coach: Dr. Tim Dalrymple Liaison Engineer: Mr. Keith Brown William Dressel (ISE) Kevin Pham (EE) Steven Stone (CSC) Sean Sullivan (ME) Phan Vu (ME)

  3. MACHINELOGIC Pipe Coupling

  4. MACHINELOGIC Project Goals & Objectives • Minimize work piece cost • Determine tool cost • Monitor wear and end of life • Implement practical metrology • Determine machining cost • Balance the process to minimize cost blackbetty420.com

  5. MACHINELOGIC Project Goals & Objectives • Provide feedback to digital manufacturing framework • Develop data acquisition system • Automate data and error logging • Monitor machine stability: chatter detection

  6. MACHINELOGIC Minimizing Work Piece Cost Cp = Cfix + Cm + Ct Cp = Cost per part Cfix= Fixed cost associated with the cost of the material Cm= Machining cost Ct= Tooling cost related to tool life and tool change time T = C (v)p (fr)q T = Tool life v = Cutting speed fr = Feed rate C, p, and q = Constants

  7. MACHINELOGIC Minimizing Cost Procedure Rearrange Cost per part equation: Take partial derivatives: Optimal cutting speed:

  8. MACHINELOGIC Determining Tool Life Through Flank Wear Width Microscope: Dino-Lite® WykoProfilometer Device Cost: $400 Device Cost: $180,000

  9. MACHINELOGIC Tool Wear Analysis Results

  10. MACHINELOGIC Calculating Optimum Machining Parameters Nominal Optimal Suggested

  11. MACHINELOGIC Machining Controller Solution INPUT SYSTEM OUTPUT Power Data Acquisition System Vibration Computer Audio Human Machine Interface LabVIEW Human Machine Interface Analyze Data Log Data

  12. MACHINELOGIC OKUMA LC-40 Lathe CM100 Microphone Kistler Accelerometer Load Controls UPC

  13. MACHINELOGIC Prototype GUI

  14. MACHINELOGIC Chatter Detection: Variance

  15. MACHINELOGIC Chatter Detection: FFT • Model boring bar as fixed-pinned cylinder • Calculate natural frequency • 1st mode = 3047 Hz • Sample signal at 10 kHz • Nyquist frequency of 5 kHz

  16. MACHINELOGIC Chatter Detection: FFT

  17. MACHINELOGIC Signal Process Analog Filtering • Blue– Sampled Frequency • Red - Aliased Frequencies

  18. MACHINELOGIC Design & Test: Low Pass Filter Sallen-Key Gain in passband: 1 Gain at cutoff (7kHz): 1/2

  19. MACHINELOGIC Low Pass Filter Results

  20. MACHINELOGIC Return on Investment Roughing Operations Optimized with Suggested Machining Parameters All Operations Optimized 1 Based on 10 hour shift 2 Based on one shift per day, 235 work days per year

  21. MACHINELOGIC Return on Investment Roughing Operations Optimized with Suggested Machining Parameters All Operations Optimized 1 Based on 10 hour shift 2 Based on one shift per day, 235 work days per year

  22. MACHINELOGIC Return on Investment Roughing Operations Optimized with Suggested Machining Parameters All Operations Optimized 1 Based on 10 hour shift 2 Based on one shift per day, 235 work days per year

  23. MACHINELOGIC Conclusion • Cost savings achieved through higher cutting speeds • Limited by stability issues • Data acquisition system can help address stability issues • Acoustic data more suitable for detecting chatter

  24. MACHINELOGIC Recommendations for Future • Develop alternative for LabVIEW • Store logged data in database • Automatically handle chatter through lathe control panel • Continue tool wear analysis • Automate tool wear measuring process • Continue power data analysis

  25. Questions?

  26. Special Thanks to: • IPPD Program • General Dynamics • Dr. Dean Bartles • Dr. Keith Stanfill • Mr. Keith Brown • Dr. Tim Dalrymple • Dr. John Schueller • Mr. Gun Lee

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