6 Process Monitoring and Control of Machining Operations Robert G. Landers University of Missouri at Rolla Introduction Force/Torque/Power Generation Cutting Force Models • Force/Torque/Power Monitoring • Force/Torque/Power Control Forced Vibrations and Regenerative Chatter Regenerative Chatter Detection • Regenerative Chatter Suppression Tool Condition Monitoring and Control Tool Failure • Tool Wear A. Galip Ulsoy University of Michigan Other Process Phenomena Burr Formation • Chip Formation • Cutting Temperature Generation Richard J. Furness Ford Motor Company Future Direction and Efforts Introduction Machining operations (., drilling, milling) are shape transformation processes in which metal is removed from a stock of material to produce a part. The objective of these operations is to produce parts with. | 6 Process Monitoring and Control of Machining Operations Robert G. Landers University of Missouri at Rolla A. Galip Ulsoy University of Michigan Richard J. Furness Ford Motor Company Introduction Force Torque Power Generation Cutting Force Models Force Torque Power Monitoring Force Torque Power Control Forced Vibrations and Regenerative Chatter Regenerative Chatter Detection Regenerative Chatter Suppression Tool Condition Monitoring and Control Tool Failure Tool Wear Other Process Phenomena Burr Formation Chip Formation Cutting Temperature Generation Future Direction and Efforts Introduction Machining operations . drilling milling are shape transformation processes in which metal is removed from a stock of material to produce a part. The objective of these operations is to produce parts with specified quality as productively as possible. Many phenomena that are detrimental to this objective occur naturally in machining operations. In this chapter we present techniques for monitoring and controlling the process phenomena that arise due to the interaction of the cutting tool and the workpiece . force generation chatter tool failure chip formation . Process monitoring is the manipulation of sensor measurements . force vision temperature to determine the state of the processes. The machine tool operator routinely performs monitoring tasks for example visually detecting missing and broken tools and detecting chatter from the characteristic sound it generates. Unmanned monitoring algorithms utilize filtered sensor measurements that along with operator inputs determine the process state Figure . The state of complex processes is monitored by sophisticated signal processing of sensor measurements that typically involve thresholding or artificial intelligence AI For more information on sensors for process monitoring the reader is referred to References 2 and 3. Process control is the manipulation of process variables .
