A Tool Replacement Decision Method And Application Based On Multi-information Integration For CNC Batch-process

Cutting tool is a significant part of machining system.Tool wear is inevitable phenomenon along with the machining progresses and the quality of workpiece could be affected.In order to avoid serious loss of quality,tools must be replaced in time.However,frequent tool replacements will not only increase tool cost but also cause production disruptions and efficiency decreasing.Therefore,it's essential to establish reasonable tool replacement policy to control the machining process.Existing empirical tool replacement methods,tool life prediction replacement methods and tool condition monitoring replacement methods have some disadvantages,such as low accuracy,parameter estimation difficulties,installation difficulties of sensors and high cost.Combining the National Science and Technology main project,"network management and intelligent monitoring system of gear automatic production line"(Number: 2011ZX04001-041),this paper aims to propose a tool replacement decision method based on the machining characteristic of the batch processing for ensuring workpiece quality,reducing production cost,and improving production efficiency.Firstly,it analyzes the two main methods of tool replacement at home and abroad,based on tool life prediction and tool wear condition monitoring,and then,it decided to take tool wear condition monitoring to decide tool replacement policy.It presents general idea of tool replacement decision method for CNC batch processing based on progress of process,power and workpiece quality information after analyzing the connection relation between those information and tool wear.Then,it proposes tool replacement decision method based on power and quality information for general CNC batch processing and tool replacement decision method based on progress,power and quality information for CNC batch processing which tool has experience replacement number.Also,it researches the acquisition of multi-source information.It presents a progress acquisition method based on PLC I/O interface,which is independent of the type of CNC system and has good expansibility.It presents a quality information acquisition method based on U-WAVE wireless transmission,which can quickly obtain the digital quality data.It presents a spindle cutting power acquisition method based on HC-33C3 power sensor which establishes the spindle cutting power calculation model based on input power.Support vector machine classification method is used to distinguish the state of power information effectively.Lastly,the tool replacement decision system is developed based on the above research contents.It introduces the system development principle,the system architecture and the function modules in detail.The communication process of the hardware and the key implementation technology are also introduced detailed.The system has been applied in the production workshop,shows a good application prospect.