Machining Control Using Integrity Models and Fatigue Thresholds

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current machining technologies lack efficient methods to determine optimal cutting conditions and ensure material integrity in avionic parts, relying on costly instrumentation and limited by the need for frequent revalidation due to tool wear and process variations.

Innovation Solution

A control system that acquires cutting condition and material parameters to construct an integrity model, using specific cutting coefficients to establish fatigue thresholds, allowing real-time monitoring and optimization of machining operations to preserve material integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional costly instrumentation and frequent revalidation methods are used, then material integrity can be ensured, but manufacturing costs and time consumption increase significantly

Engineering Contradiction:

Improvematerial integrityVSAvoidrevalidation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-establishing an integrity model during a learning phase that captures the relationship between machining parameters and material integrity. This model is constructed beforehand using historical data and can be repeatedly applied during production without requiring frequent revalidation, thus ensuring material integrity while reducing time consumption.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses copying by creating a virtual integrity model that replicates the complex relationships between machining parameters and material integrity. Instead of performing physical revalidation tests, the system copies the essential integrity relationships into a computational model that can be rapidly evaluated, significantly reducing revalidation time while maintaining reliability.

Inventive Principle:

Principle #26Copying

2Reliability

If traditional instrumentation methods are used to monitor machining, then material integrity can be assessed, but device complexity and cost increase

Engineering Contradiction:

Improvematerial integrity monitoringVSAvoidinstrumentation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical instrumentation systems with a computational integrity model. Instead of using physical sensors and measurement devices to monitor material integrity, the system uses a mathematical model that processes machining parameters to assess integrity, thereby reducing device complexity while maintaining monitoring capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary integrity model that mediates between machining parameters and material integrity assessment. This computational intermediary translates complex physical relationships into processable data, simplifying the monitoring system while ensuring accurate integrity evaluation without requiring direct complex instrumentation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If conventional machining control methods are used, then manufacturing processes can be maintained, but adaptability to process variations and tool wear decreases

Engineering Contradiction:

Improveadaptability to process variationsVSAvoidconformity guarantee

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies dynamics by making the machining control adaptive rather than static. The integrity model continuously evaluates current machining parameters against established relationships, allowing the system to adapt to process variations and tool wear in real-time while maintaining conformity guarantees through dynamic adjustment of machining conditions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent uses parameter changes by modifying machining parameters based on the integrity model's assessments. When the model detects deviations due to tool wear or process variations, it recommends or automatically adjusts parameters such as cutting speed, feed rate, or depth of cut to maintain material integrity and conformity, thereby improving adaptability without sacrificing reliability.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12055915B2System for controlling machining of a part

Publication Date: 2024.08.06 AIRBUS (SAS)

AI summary

This control system takes into account the thermomechanical aspects of materials to quickly and easily determine optimal cutting conditions and to automatically control machining to preserve the integrity of the workpiece. This system includes an acquisition module configured to acquire values of a set of input parameters relating to cutting conditions and material properties of the piece, and a microprocessor configured for determining at least one operating cutting parameter representative of a cutting signal from the machining apparatus using a set of output parameters of an integrity model previously constructed during a learning phase. The integrity model connects the set of input parameters to the set of output parameters comprising specific cutting coefficients representative of the material integrity of the piece, and establishes at least one fatigue threshold of the at least one cutting operating parameter. The fatigue threshold allows control of the progress of cutting operations.