System and method for automated machining process planning and optimization

Abstract

The invention relates to a computer-implemented system for automated machining process planning, comprising: a feature extraction module configured to analyze 2D drawings and 3D CAD models to identify machining features; a cutting tool selection module configured to match extracted features with suitable cutting tools; a process planning module configured to generate optimized machining plans; a cutting tool path generation module configured to create efficient cutting tool paths; characterized in that the system further comprises: a parameter optimization module incorporating chip formation physics to refine machining parameters; a collision detection module configured to identify and resolve potential collisions; and means for integrating the modules into a unified software platform.

Description

[0001] DESCRIPTION

[0002] SYSTEM AND METHOD FOR AUTOMATED MACHINING PROCESS PLANNING AND OPTIMIZATION

[0003] The present disclosure generally relates to automated machining process planning and optimization, and in particular, to systems and methods for integrating feature extraction, cutting tool selection, process planning, cutting tool path generation, parameter optimization, and collision detection in a unified software platform for computer numerical control (CNC) machining.

[0004] Computer-aided manufacturing (CAM) systems have become integral to modem machining processes, enabling the creation of complex parts with high precision. These systems typically involve separate modules for feature extraction, cutting tool selection, process planning, and cutting tool path generation. However, the fragmented nature of existing solutions often leads to inefficiencies and potential errors in the machining process. Additionally, tasks such as cutting tool selection, process planning, and cutting tool path generation heavily rely on human expertise, which can introduce variability and inefficiencies.

[0005] One significant challenge in current CAM systems is the lack of comprehensive integration between various stages of the machining process. For example, US Patent No. 10,762,699 discloses a machining parameter automatic generation system that uses machine learning for feature recognition and parameter selection. While this system addresses some aspects of automation, it does not provide a fully integrated solution that encompasses all stages of the machining process, from feature extraction to collision detection.

[0006] It has been appreciated that a unified and comprehensive automated machining process planning system is needed that overcomes one or more of these problems.

[0007] The object of the present invention is to provide a unified and comprehensive automated machining process planning system that addresses the lack of integration between various stages of the machining process in existing computer-aided manufacturing (CAM) systems. The object of the invention is to overcome the inefficiencies and potential errors arising from the fragmented nature of current CAM solutions, which typically involve separate modules for feature extraction, cutting tool selection, process planning, and cutting tool path generation, and to minimize the impact of human errors in these processes.The object of the invention is to deliver a fully integrated solution that encompasses all stages of the machining process, from feature extraction to collision detection, thereby streamlining and optimizing the overall machining workflow in manufacturing environments.

[0008] A computer-implemented system for automated machining process planning, comprising: a feature extraction module configured to analyze 2D drawings and 3D CAD models to identify machining features; a cutting tool selection module configured to match extracted features with suitable cutting tools; a process planning module configured to generate optimized machining plans; a cutting tool path generation module configured to create efficient cutting tool paths; characterised in that the system further comprises: a parameter optimization module incorporating chip formation physics to refine machining parameters; a collision detection module configured to identify and resolve potential collisions; and means for integrating the modules into a unified software platform.

[0009] The system operates by seamlessly integrating multiple specialized modules within a unified software platform. Initially, the feature extraction module employs advanced algorithms to analyze 2D drawings and 3D CAD models, identifying relevant machining features. These extracted features are then passed to the cutting tool selection module, which utilizes a comprehensive database to match each feature with suitable cutting tools. The process planning module subsequently generates optimized machining plans, considering factors such as efficiency and resource utilization. Building on this, the cutting tool path generation module creates efficient cutting tool paths tailored to the specific machining operations. The parameter optimization module further refines the process by incorporating chip formation physics, adjusting parameters like feed rates and cutting speeds for optimal performance. Throughout the planning and execution phases, the collision detection module continuously monitors for potential interferences, identifying and resolving any issues to ensure safe operation. This integrated approach allows for dynamic optimization across all stages of the machining process, potentially improving overall efficiency, accuracy, and quality of the manufactured parts. In a preferred embodiment of the computer-implemented system, wherein the cutting tool selection module is further configured to optimize cutting tool selection based on cutting tool geometry, material compatibility, cutting tool life, cost, and delivery time.

[0010] Optimizing cutting tool selection based on multiple factors like geometry, material compatibility, cutting tool life, cost, and delivery time can potentially lead to more efficientmachining processes, reduced production costs, and improved overall manufacturing productivity.

[0011] In a preferred embodiment of the computer-implemented system, wherein the process planning module is further configured to specify an order of operations and assign cutting tools to features.

[0012] Intelligently sequencing operations and matching cutting tools to specific features can significantly enhance machining efficiency, minimize cutting tool changes, and optimize resource utilization throughout the manufacturing process.

[0013] In a preferred embodiment of the computer-implemented system, wherein the parameter optimization module is configured to refine feed rates and spindle speeds based on chip formation physics.

[0014] By incorporating chip formation physics into the optimization of feed rates and spindle speeds, machining processes can achieve improved surface finish, extended cutting tool life, low machining times, and enhanced overall part quality.

[0015] In a preferred embodiment of the computer-implemented system, further comprising means for real-time monitoring of machining processes and making adjustments during execution.

[0016] Real-time monitoring and adjustment capabilities enable dynamic optimization of machining parameters, potentially reducing errors, improving part quality, and increasing overall process efficiency.

[0017] A computer-implemented method for automated machining process planning, the method comprising: analyzing, by a feature extraction module, 2D drawings and 3D CAD models to identify machining features; matching, by a cutting tool selection module, extracted features with suitable cutting tools; generating, by a process planning module, optimized machining plans; creating, by a cutting tool path generation module, efficient cutting tool paths; refining, by a parameter optimization module incorporating chip formation physics, machining parameters; identifying and resolving, by a collision detection module, potential collisions; and integrating the modules into a unified software platform.

[0018] The method operates through a series of interconnected steps executed by specialized modules within an integrated software platform. Initially, the feature extraction module employs advanced algorithms to analyze 2D drawings and 3D CAD models, identifying relevant machining features. These extracted features are then processed by the cutting tool selectionmodule, which utilizes a comprehensive database to match each feature with suitable cutting tools. The process planning module subsequently generates optimized machining plans, considering factors such as efficiency and resource utilization. Building on this plan, the cutting tool path generation module creates efficient cutting tool paths tailored to the specific machining operations. The parameter optimization module further refines the process by incorporating chip formation physics, adjusting parameters like feed rates and cutting speeds for optimal performance. Throughout the planning and execution phases, the collision detection module continuously monitors for potential interferences, identifying and resolving any issues to ensure safe operation. By integrating these modules into a unified software platform, the method enables dynamic optimization across all stages of the machining process, potentially improving overall efficiency, accuracy, and quality of the manufactured parts. This integration also contributes to reduced production time, increased productivity, lower manufacturing costs, reduced cutting tool expenses, and shorter engineering lead times, providing significant additional benefits across the manufacturing workflow.

[0019] In a preferred embodiment of the computer-implemented method, wherein the cutting tool selection module is further configured to optimize cutting tool selection based on cutting tool geometry, material compatibility, cutting tool life, cost, and delivery time.

[0020] Optimizing cutting tool selection based on multiple factors like geometry, material compatibility, cutting tool life, cost, and delivery time can potentially lead to more efficient machining processes, reduced production costs, and improved overall manufacturing productivity.

[0021] In a preferred embodiment of the computer-implemented method, wherein the process planning module is further configured to specify an order of operations and assign cutting tools to features.

[0022] Intelligently sequencing operations and matching cutting tools to specific features can significantly enhance machining efficiency, minimize cutting tool changes, and optimize resource utilization throughout the manufacturing process.

[0023] In a preferred embodiment of the computer-implemented method, wherein the parameter optimization module is configured to refine feed rates and spindle speeds based on chip formation physics.By incorporating chip formation physics into the optimization of feed rates and spindle speeds, machining processes can achieve improved surface finish, extended cutting tool life, and enhanced overall part quality.

[0024] In a preferred embodiment of the computer-implemented method, further comprising means for real-time monitoring of machining processes and making adjustments during execution.

[0025] Real-time monitoring and adjustment capabilities enable dynamic optimization of machining parameters, potentially reducing errors, improving part quality, and increasing overall process efficiency.

[0026] Seamless integration of diverse machining modules into a unified platform enables comprehensive optimization across the entire process chain, potentially enhancing efficiency, accuracy, and quality in computer numerical control (CNC) manufacturing operations.

[0027] By orchestrating a seamless workflow from feature extraction to collision detection, this integrated approach enables dynamic optimization across all stages of the machining process, potentially elevating overall efficiency, accuracy, and quality of manufactured parts.

Claims

CLAIMS1. A computer-implemented system for automated machining process planning, comprising: a feature extraction module configured to analyze 2D drawings and 3D CAD models to identify machining features;a cutting tool selection module configured to match extracted features with suitable cutting tools;a process planning module configured to generate optimized machining plans;a cutting tool path generation module configured to create efficient cutting tool paths; characterised in that the system further comprises:a parameter optimization module incorporating chip formation physics to refine machining parameters;a collision detection module configured to identify and resolve potential collisions; and means for integrating the modules into a unified software platform.

2. The computer-implemented system of claim 1, wherein the cutting tool selection module is further configured to optimize cutting tool selection based on cutting tool geometry, material compatibility, cutting tool life, cost, and delivery time.

3. The computer-implemented system of claim 1 or 2, wherein the process planning module is further configured to specify an order of operations and assign cutting tools to features.

4. The computer-implemented system of any of claims 1 to 3, wherein the parameter optimization module is configured to refine feed rates and spindle speeds based on chip formation physics.

5. The computer-implemented system of any preceding claim, further comprising means for real-time monitoring of machining processes and making adjustments during execution.

6. A computer-implemented method for automated machining process planning, the method comprising:analyzing, by a feature extraction module, 2D drawings and 3D CAD models to identify machining features;matching, by a cutting tool selection module, extracted features with suitable cutting tools; generating, by a process planning module, optimized machining plans;creating, by a cutting tool path generation module, efficient cutting tool paths; characterised in that the method further comprises:refining, by a parameter optimization module incorporating chip formation physics, machining parameters;identifying and resolving, by a collision detection module, potential collisions; and integrating the modules into a unified software platform.

7. The computer-implemented method of claim 6, wherein the cutting tool selection module is further configured to optimize cutting tool selection based on cutting tool geometry, material compatibility, cutting tool life, cost, and delivery time.

8. The computer-implemented method of claim 6 or 7, wherein the process planning module is further configured to specify an order of operations and assign cutting tools to features.

9. The computer-implemented method of any of claims 6 to 8, wherein the parameter optimization module is configured to refine feed rates and spindle speeds based on chip formation physics.

10. The computer-implemented method of any preceding claim, further comprising means for real-time monitoring of machining processes and making adjustments during execution.