cost optimization in machining tool wear monitoring tool wear monitoring practical tool wear...
Post on 15-Jan-2016
230 views
TRANSCRIPT
INTELLIGENT MACHINING & PROCESS CONTROL :
Cost optimization in machining
โข Tool wear monitoringโข Practical tool wear metrology
โข Continuous optimization
โข Process stability monitoring โข Acoustic and vibration monitoring
โข LabVIEW based signal processing
Sponsor: General Dynamics - OTSCoach: Dr. Tim DalrympleLiaison Engineer: Mr. Keith Brown
William Dressel (ISE)Kevin Pham (EE)Steven Stone (CSC)Sean Sullivan (ME)Phan Vu (ME)
Team:
MACHINELOGIC
Pipe Coupling
Minimize work piece costDetermine tool cost
โ Monitor wear and end of lifeโ Implement practical metrology
Determine machining costBalance the process to minimize cost
blackbetty420.com
Project Goals & Objectives MACHINELOGIC
Project Goals & Objectives
Provide feedback to digital manufacturing frameworkDevelop data acquisition systemAutomate data and error loggingMonitor machine stability: chatter
detection
MACHINELOGIC
Minimizing Work Piece CostCp = 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
MACHINELOGIC
Minimizing Cost ProcedureRearrange Cost per part equation:
Take partial derivatives:
Optimal cutting speed:
๐ถ๐๐๐๐ก = ๐๐๐๐ฅ๐๐ +แบ๐๐ท๐๐ฟแปแ๐๐๐ฃ๐๐+ ๐ก๐โ๐๐ +๐ถ๐ก๐๐ถ๐ฃโ๐+1๐๐โ๐+1แ
๐๐ถ๐๐๐๐ก๐๐ฃ = แบ๐๐ท๐๐ฟแปแโ ๐๐๐ฃ2๐๐+๐ก๐โ๐๐ +๐ถ๐ก๐๐ถ๐๐โ๐+1 แบ๐โ1แป๐ฃ๐โ2 = 0
๐๐ถ๐๐๐๐ก๐๐๐ = แบ๐๐ท๐๐ฟแปโ ๐๐๐ฃ๐๐2+๐ก๐โ๐๐ +๐ถ๐ก๐๐ถ๐ฃโ๐+1 แบ๐โ1แป๐๐๐โ2เตจ= 0
๐ฃ๐๐๐ก =แ๐ถ๐๐
แบ๐โ1แปแบ๐ก๐โ๐๐ +๐ถ๐ก๐แป๐๐๐๐ฅ๐ 1/๐
MACHINELOGIC
Determining Tool Life Through Flank Wear Width
Microscope: Dino-Liteยฎ Wyko Profilometer
Device Cost: $400
Device Cost: $180,000
MACHINELOGIC
Tool Wear Analysis Results
MACHINELOGIC
Calculating Optimum Machining Parameters
Nominal Cutting Speed
Nominal Feed Rate
6338 in/min
.02 in/rev
Suggested Cutting Speed
Suggested FeedRate
6972 in/min(~110%)
.02 in/rev
Optimal Cutting Speed
Optimal Feed Rate
9066 in/min
.02 in/rev
Nominal SuggestedOptimal
MACHINELOGIC
Machining Controller Solution INPUT SYSTEM OUTPUT
Human Machine Interface
Data Acquisition System
Computer
LabVIEW
Analyze Data
Human Machine Interface
Log Data
MACHINELOGIC
Power
Vibration
Audio
OKUMA LC-40 Lathe
Load Controls UPC
CM100 Microphone Kistler Accelerometer
MACHINELOGIC
Prototype GUIMACHINELOGIC
Chatter Detection: Variance
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
๐๐= ๐ท๐๐๐ เถจ ๐ฌ๐ฐ๐๐จ๐๐ณ๐
MACHINELOGIC
Chatter Detection: FFTMACHINELOGIC
Signal Process Analog Filtering
Blue โ Sampled Frequency Red - Aliased Frequencies
MACHINELOGIC
Sallen-Key Gain in passband: 1
Gain at cutoff (7kHz): 1/2
Design & Test: Low Pass Filter
MACHINELOGIC
Low Pass Filter ResultsMACHINELOGIC
Initial Investment
Cost Per Unit
Units Ordered
Total Investment
Cost Saved
Per Part
Parts Produced Per Shift1
Parts Produced Per Year2
Cost Saved
Per Year2 R.o.I.
Prototype Investment
$20,000 $12,808 1 $32,808 $0.29 56 13,351 $3,894 11.9%
Industry Level Investment
$106,000 $8,893 6 $159,358 $0.29 340 80,110 $23,36514.7%
1 Based on 10 hour shift2 Based on one shift per day, 235 work days per year
Initial Investment
Cost Per Unit
Units Ordered
Total Investment
Cost Saved
Per Part
Parts Produced Per Shift1
Parts Produced Per Year2
Cost Saved
Per Year2 R.o.I.
Prototype Investment
$20,000 $12,808 1 $32,808 $0.29 58 13,749 $9,36228.5%
Industry Level Investment
$106,000 $8,893 6 $159,358 $0.29 351 82,494 $56,17335.2%
Roughing Operations Optimized with Suggested Machining Parameters
All Operations Optimized
Return on InvestmentMACHINELOGIC
Initial Investment
Cost Per Unit
Units Ordered
Total Investment
Cost Saved
Per Part
Parts Produced Per Shift1
Parts Produced Per Year2
Cost Saved
Per Year2 R.o.I.
Prototype Investment
$20,000 $12,808 1 $32,808 $0.29 56 13,351 $3,894 11.9%
Industry Level Investment
$106,000 $8,893 6 $159,358 $0.29 340 80,110 $23,36514.7%
1 Based on 10 hour shift2 Based on one shift per day, 235 work days per year
Initial Investment
Cost Per Unit
Units Ordered
Total Investment
Cost Saved
Per Part
Parts Produced Per Shift1
Parts Produced Per Year2
Cost Saved
Per Year2 R.o.I.
Prototype Investment
$20,000 $12,808 1 $32,808 $0.29 58 13,749 $9,36228.5%
Industry Level Investment
$106,000 $8,893 6 $159,358 $0.29 351 82,494 $56,17335.2%
Roughing Operations Optimized with Suggested Machining Parameters
All Operations Optimized
Return on InvestmentMACHINELOGIC
Initial Investment
Cost Per Unit
Units Ordered
Total Investment
Cost Saved
Per Part
Parts Produced Per Shift1
Parts Produced Per Year2
Cost Saved
Per Year2 R.o.I.
Prototype Investment
$20,000 $12,808 1 $32,808 $0.29 56 13,351 $3,894 11.9%
Industry Level Investment
$106,000 $8,893 6 $159,358 $0.29 340 80,110 $23,36514.7%
1 Based on 10 hour shift2 Based on one shift per day, 235 work days per year
Initial Investment
Cost Per Unit
Units Ordered
Total Investment
Cost Saved
Per Part
Parts Produced Per Shift1
Parts Produced Per Year2
Cost Saved
Per Year2 R.o.I.
Prototype Investment
$20,000 $12,808 1 $32,808 $0.29 58 13,749 $9,36228.5%
Industry Level Investment
$106,000 $8,893 6 $159,358 $0.29 351 82,494 $56,17335.2%
Roughing Operations Optimized with Suggested Machining Parameters
All Operations Optimized
Return on InvestmentMACHINELOGIC
Conclusion
Cost savings achieved through higher cutting speeds
Limited by stability issuesData acquisition system can help address
stability issuesAcoustic data more suitable for detecting
chatter
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
MACHINELOGIC
Questions?
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