Machining Process Optimization with ISO 10303-238
Transcript of Machining Process Optimization with ISO 10303-238
Machining Process Optimization Machining Process Optimization with ISO 10303with ISO 10303--238238
Leon Leon XuXuThe Boeing CompanyThe Boeing Company
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Machining Process OptimizationMachining Process Optimization
Machining ParametersMachining Parameters
Machine ConstraintsMachine Constraints
ProductivityProductivity
Cutting ForceCutting Force
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Machining System ConstraintsMachining System Constraints
Cutting tools
Machine/spindle capability
System structural dynamics
-Spindle power, torque and speed-Spindle bearings-Tool holder-Axis torque and speed
-Machine/spindle/fixture-Cutting tool/holder/spindle
-Edge rigidity-Surface velocity-Rotational speed-Wear
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Affecting FactorsAffecting Factors
Machining parameters
Material properties
Cutting tool dimensions
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Cutting Parameters and Path GeometryCutting Parameters and Path Geometry
Removed MaterialAxial Depth
Radial Depth
Center Line
Rotation Speed
Feed Rate
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Information in MInformation in M--G Code (ISO 6983)G Code (ISO 6983)Rotation Speed
Feed Rate
Center Line
N1 G49N1 G49N2 T10M6N2 T10M6N3 G90N3 G90N4 G43.5H10I0J0K1N4 G43.5H10I0J0K1N5 M3S7958N5 M3S7958N6 G1X0Y0Z30F0N6 G1X0Y0Z30F0N7 X99.8497YN7 X99.8497Y--149.3009Z10149.3009Z10N8 G0Z4N8 G0Z4N9 ZN9 Z--22N10 G1ZN10 G1Z--4F8355.94F8355.9N11 X89.8497YN11 X89.8497Y--165.6804165.6804N12 X88.6399YN12 X88.6399Y--167.6621167.6621N13 X84.5787YN13 X84.5787Y--173.9364173.9364N14 X79.9216YN14 X79.9216Y--180.683180.683N15 X75.4355YN15 X75.4355Y--186.7118186.7118N16 X69.814YN16 X69.814Y--193.8761193.8761N17 X65.1231YN17 X65.1231Y--199.3388199.3388N18 X62.8337YN18 X62.8337Y--201.9142201.9142N19 X53.9447YN19 X53.9447Y--211.9142211.9142……………………
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Information in ISO 10303Information in ISO 10303--238238
Removed MaterialAxial Depth
Radial Depth
Rotation Speed
Feed Rate
Center Line
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CrossCross--Sectional Area in ISO 10303Sectional Area in ISO 10303--238238
ISO 10303-238:2007 Technical Corrigendum 1
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Examples of CrossExamples of Cross--Sectional AreaSectional Area
ADmax
RDmax
CG CG CG
ADmax ADmax
RDmax RDmax
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Engagement LocationsEngagement Locations
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Engagement StartEngagement Start--End ConditionsEnd Conditions
RD RDRD RD
Climb Milling Conventional Milling Slotting (Channel Cutting) Center Cutting
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Maximum Engagement ConditionsMaximum Engagement Conditions
RD
AD
RD
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Current Optimization ProcessCurrent Optimization Process
STEP-NCWork Plan(Original)
3-D Stock Model
ISO 6983NC Program
(Original)
3-DSimulation
STEP-NCWork Plan
(Cross-Section)
STEP-NCWork Plan
(Optimized)Optimization
Cross-Section
ISO 6983NC Program(Optimized)
CNC Machine
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Future Optimization ProcessFuture Optimization Process
STEP-NCWork Plan
(Cross-Section)
STEP-NCWork Plan
(Optimized)Optimization CNC Machine
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Optimization MethodsOptimization Methods
Volume Based OptimizationVolume Based OptimizationForce Based OptimizationForce Based OptimizationTool Wear OptimizationTool Wear OptimizationConstant Chip OptimizationConstant Chip OptimizationUserUser--defined Optimizationdefined Optimization
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Radial ChipRadial Chip--Thinning CompensationThinning Compensation
tp
tm tm’
fd fd’
tp’
RDRD
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Axial ChipAxial Chip--Thinning CompensationThinning Compensation
tp
tm tm’
fd fd’
tp’
ADAD
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Feed/Tooth Feed/Tooth vsvs Radial ImmersionRadial Immersion
-
0.025
0.050
0.075
0.100
0.125
0.150
0.175
0.200
0% 25% 50% 75% 100%
fz(m
m)
D=10mm
D=8mm
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Feed and Radial Depth (T7)Feed and Radial Depth (T7)
0100200300400500600700800900
1000
1 41 81 121 161 201 241 281 321 361 401 441 481 521 561 601 641 681
Orig
Opt
0123456789
10
1 39 77 115 153 191 229 267 305 343 381 419 457 495 533 571 609 647 685
RD
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Feed and Radial Depth (T9)Feed and Radial Depth (T9)
0
200
400
600
800
1000
1200
1400
1600
1 41 81 121 161 201 241 281 321 361 401 441 481 521 561 601 641 681
Orig
Opt
0
1
2
3
4
5
6
7
8
1 39 77 115 153 191 229 267 305 343 381 419 457 495 533 571 609 647 685
RD
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Feed OptimizationFeed Optimization
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Optimization for Different MachinesOptimization for Different Machines
Machining
NCProgram
Opt. NCProgram
Optimization
Machining
Opt. NCProgram
Optimization
Machining
Opt. NCProgram
Optimization
STEP-NC
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Optimization of Different ProgramsOptimization of Different Programs
NCProgram
Machining
Opt. NCProgram
Optimization
NCProgram
NCProgram
STEP-NC STEP-NCSTEP-NC
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Machining Process OptimizationMachining Process Optimization
Design Programming MachiningCADModel
NCProgram
-- Feed and speedFeed and speed
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Machining Planning OptimizationMachining Planning Optimization
Design Programming MachiningCADModel
NCProgram
-- Feed and speedFeed and speed-- Path trajectory, radial and axial depths, number of Path trajectory, radial and axial depths, number of
passespasses……
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Machining Design OptimizationMachining Design Optimization
Design Programming MachiningCADModel
NCProgram
-- ““Machining friendlyMachining friendly”” feature designfeature design
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Total Manufacturing OptimizationTotal Manufacturing Optimization
Design Programming MachiningCADModel
NCProgram
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