NC Machining Force Prediction for Adaptive Tool Path Optimization
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Solution Overview
Problem
Existing optimization methods for numerically controlled machining require high computing effort, limiting flexibility and ability to account for varying configurations during machining, and are often restricted to offline calculations, making it difficult to adapt to changes in tool path or configuration parameters during the machining process.
Innovation Solution
A method that calculates forces occurring during machining, allowing for adjustments both offline before machining and online during machining, by determining geometric interactions between the tool and workpiece, and using these interactions to adjust machining parameters in real-time, thereby improving the adaptability and accuracy of the machining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optimization calculations are performed completely offline before machining, then manufacturing precision can be improved by accounting for forces, but adaptability to changes during machining is lost
Solution Approach 1:
The optimization calculation is divided into two segments: an offline phase that determines geometric interaction data and a relationship model, and an online phase that uses these pre-computed elements to calculate forces during machining. This segmentation allows the system to benefit from both offline precision and online adaptability.
Solution Approach 2:
Geometric interaction data and the force relationship model are determined in advance before machining begins. This preliminary computation of the interaction geometry and force relationships enables rapid online calculations during machining without requiring complete re-simulation.
2Manufacturing precision
If complete machining simulation is performed offline, then forces can be accurately predicted, but computing effort becomes too high for real-time adaptation
Solution Approach 1:
The computational process is segmented into an offline phase that computes geometric interaction data and relationship models, and an online phase that performs rapid force calculations using pre-computed elements. This avoids the need for complete real-time simulation while enabling timely force prediction.
Solution Approach 2:
The system changes the computational parameters from complete geometric simulation to using pre-determined geometric interaction data and relationship models. This parameter change reduces computing effort while maintaining force prediction accuracy.
3Ease of manufacture
If machining parameters are fixed before processing, then offline optimization can be performed, but flexibility to adjust during machining is reduced
Solution Approach 1:
The system transitions from static pre-determined parameters to dynamic parameter adjustment during machining. Configuration parameters can be modified online, and the force calculation adapts to these changes using the pre-computed geometric interaction data and relationship models.
Solution Approach 2:
Configuration parameters are allowed to change during machining processing. The system maintains flexibility by using pre-computed geometric interaction data that can accommodate parameter variations without requiring complete re-simulation.
Data Source
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AI summary
In order to be able to take into account machining configurations more flexibly, a method for optimizing numerically controlled machining of a workpiece (WS) includes ascertaining geometric interaction data (ID). A relationship between a force to be expected and a configuration parameter of the machining is determined on the basis of the interaction data (ID). The force is calculated during the machining on the basis of the relationship and a current value of the at least one configuration parameter. The machining is adapted depending on the calculated force.