具雙向溝通介面之切削異常線上智慧監控與加工製程優化方法之研究

Development of an On-Line Monitoring Control System with Two-Way Communication Interface for Abnormal Machining and a Machining Process Improvement Method

周聖軒(Shih-Sheng Chou)

指導教授 ： 王世明

中原大學/工學院/機械工程研究所/碩士(2013年)

https://doi.org/10.6840/cycu201400150

摘要

本研究主要目的是改善先前發展之CNC工具機線上切削異常智能監控系統，系統包含：(1)切削異常診斷模組;(2)控制器資訊雙向即時擷取模組。除原有顫振、刃口積屑、斷刀三種診斷法則外，本研究新增過負荷切削診斷法則，使機台或刀具可避免因切削阻抗過大而造成損壞。此外，斷刀診斷法則無法診斷加工初期即發生之斷刀現象，改善後斷刀診斷法則可於2秒內診斷切削異常並在3秒內完成切削抑制。系統診斷方法使用訊號變化特徵法及快速傅立葉轉換法進行分析，另外利用 Fanuc 之 CNC Open Api Spec軟體撰寫控制器資訊雙向擷取模組，擷取即時加工資訊配合切削異常診斷模組提高系統診斷準確率。本研究另一部分為車削製程參數優化法建立，參數優化以提升加工效率為主，由實驗歸納出進給量對應振動均方根值及進給量對應表面粗糙度之特徵曲線，然後使用曲線擬合求得特徵曲線方程式，再藉由特徵曲線方程式計算振動容許值。在考慮刀具容許負載、振動容許值等條件下制定加工參數演算法則，最後使用MATLAB將演算法則實際可運用於產線之系統，實驗結果顯示該製程加工效率提升2倍。

關鍵字

加工參數優化 ； 過負荷振動 ； 斷刀

並列摘要

The main purpose of this research is to improve the previously on-line cutting CNC machine tools abnormal intelligent monitoring system, the system includes: (1) abnormal cutting diagnosis module; (2) bi-direction real-time controller information acquisition module. The original system has three types of abnormal cutting diagnosis algorithms for chatter, built-up-edge, and cutter breakage. This study adds new monitoring function for the overload cutting, and it can avoid tools or machine damage due to excessive cutting resistance. Because the cutter breakage diagnosis algorithm can not detect cutter breakage occurring at every initial cutting process, improved the algorithm was proposed in this study. The new algorithm can detect abnormality within 2 seconds and proceed the necessary control within 3 seconds. The system uses signal variation characteristics analysis and Fast Fourier Transfer instead of complex single transfer methods for signal analysis. Fanuc Open CNC Api Spec was used to develop a program which can real-time extract the machine state parameters from the CNC controller with abnormal cutting diagnosis module to improve the diagnosis accuracy. The other part of this study is to establish parameters optimization method for turning process to enhance the machining efficiency. The characteristic curves of feed to root mean square of vibration and the feed to surface roughness were first built with use of curve-fitting, the characteristic curve equations were then obtained for calculation of the allowable vibration. Considering the tool load and allowable vibration value, the program made with Matlab can solve and recommend the optimal cutting parameters for turning process. The experimental results showed that the machining efficiency can be increased two times by the optimization algorithm.

並列關鍵字

overload cutting vibration ； cutter breakage ； machining parameter optimization

參考文獻

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