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Monitoring of the average cutting forces from controller signals using artificial neural networks

Bugdayci Nevzat Bircan, Wegener Konrad, Postel Martin

Journal of Machine Engineering

2022

Vol. 22, No. 4

54--70

A new approach is presented to monitor the average cutting forces that are used for the calculation of the average cutting coefficients through neural networks using available controller signals. The cutting forces and the relevant controller signals are measured using a dynamometer and commercially available software supplied by the controller manufacturer in the calibration stage. Then a neural network is trained, which treats these controller signals as inputs and the cutting forces as the outputs. Finally, the average cutting forces for a new milling operation are predicted using the trained neural network without using a dynamometer. The proposed approach is validated using an experimental study, where a good match between predictions and measured forces is achieved. It is also shown that cutting coefficients can be calibrated and stability lobe diagrams can be generated using this method.

Operator integrated – concept for manufacturing intelligence

Wegener Konrad, Weikert Sascha, Mayr Josef, Maier Markus, Ali Akbari Vahid Ostad, Postel Martin

Journal of Machine Engineering

2021

Vol. 21, No. 4

5--28

Increasing autonomy and sustainability are major goals in manufacturing. Main technological trends provide enablers for achieving these goals and need to be implemented and combined in manufacturing machinery in a suitable manner. The paper exposes a vision of modern manufacturing machines, where the complexity of manufacturing processes is handled within the manufacturing machine and a simplistic front end is presented to the operator, which means that major elements of operators’ tasks are fulfilled by the intelligence of the machine. Research vectors paving the ground for this concept from different points of view are then discussed. Research is presented on intelligent grinding, intelligent recognition and suppression of chatter, adaptive thermal and motion error compensation exploting also self-learning abilities. It is necessary to point out, that not only intelligent mastering of process and machine becomes more and more important but communications among machine tools enabling process chain overarching intelligent approaches and creating intelligent factories.