Research And Development Of Cutting Process Monitoring System Based On Digital Twin

With the continuous improvement of automation and complexity of machining system,on-line monitoring technology of cutting process has become an important guarantee to improve production efficiency and reduce production cost.Cutting process monitoring depends on a number of cutting conditions,which has the characteristics of many data sources and uncertain influence factors.It is difficult to realize reliable monitoring of the cutting process under different cutting conditions through monitoring technology based on signal of numerical control system or sensor,which affects the machining quality.As an important tool to improve the monitoring efficiency,digital twin can integrate multi-source data integration,cutting process monitoring and virtual simulation analysis.Digital twin provides an effective means for the simulation and monitoring of cutting process under different cutting conditions.In this thesis,the cutting process monitoring system is studied based on the function and characteristics of digital twin.The monitoring system realizes the dynamic simulation and monitoring of the cutting process under different cutting conditions.The main research work of this thesis is listed as follows:Firstly,according to the characteristics of multi-source data and time-varying process in the cutting monitoring process,the requirements of the cutting process monitoring system are analyzed.On this basis,the general architecture of cutting process monitoring system based on digital twin is proposed.The digital twin monitoring system is designed in detail from physical entity,virtual entity,connection and interaction,twin data and service module.Based on the machining characteristics and application requirements of the cutting process,the key technologies involved in the digital twin monitoring system are analyzed.Secondly,the key technologies involved in the cutting process monitoring system based on digital twin are studied.The research includes multi-source data acquisition and integration technology,cutting process data modeling technology based on OPC UA,cutting force prediction technology based on physical simulation,geometric simulation technology of cutting process based on Direct 3D,and integration and service of functional model of monitoring system.Finally,on the basis of the above research,the software development,deployment and system test of the cutting process monitoring system based on digital twin are completed.Combined with the cutting mode and characteristics of whirling milling,the model coefficient solution and simulation method for predicting the cutting force of whirling milling are studied.Through whirling milling experiments,the performance and function of the monitoring system are tested,and the feasibility of the monitoring system based on digital twin for dynamic simulation analysis and abnormal monitoring of cutting process is verified.