KE22 FINAL YEAR PROJECT Modeling and Simulation of Milling Forces SIMTech Project Ryan Soon, Henry...

KE22 FINAL YEAR PROJECTModeling and Simulation of Milling ForcesSIMTech Project

Ryan Soon, Henry Woo, Yong BoonApril 9, 2011Confidential – Internal Only

2| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

BACKGROUND AND OBJECTIVE

Singapore Institute of Manufacturing Technology (SIMTech)

Knowledge Engineering

Research

Industry

Students

SIMTech as a company

– Develops high value manufacturing technology and human capital

– Enhance competitiveness of Singapore manufacturing industry

Milling process

– One of the many manufacturing processes research upon

3| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

INTRODUCTION TO MILLING

A common machining process used in material manufacturing

Customized solid material can be designed and created

Consist of a milling machine, workpiece, fixture, and cutter

Can be manually operated, mechanically automated or digitally automated via Computer Numerical Control (CNC)

Scope is limited to CNC type of milling machine and its processes

4| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

CONCEPT MAP

5| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

Problems Encountered During Milling Process

6| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

Current Milling Process

7| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

Target Goal for Milling Company

8| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

An Intelligent Tool Wear and Failure Prognostic System

MILLING PROCESS SETUP

Reduce Downtime

Improved Utilization

Pre-Processing and Feature

Selection

KE Models and Accuracy Evaluation

Knowledge Base

GUI Feedback

Milling Process

Sensor SetupData

AcquisitionTool Wear

MeasurementSensory Data

Store

9| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

PROJECT SCOPE AND OBJECTIVES

No Force Feature AE Features

1 Maximum Force Level Peak to peak

2 Total Amplitude of Cutting Force Skewness

3 Amplitude Ratio Kurtosis

4 Average Force Mean of band power

KE Techniques

Under Investigation

10| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

THE END

Q&A

11| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

BACKUP

12| KE22 FYP, Modeling and Simulation of Milling Forces | April 9, 2011 | Confidential – Internal Only

INITIAL KE TECHNIQUES EVALUATION

Neural Network

– No model required ()

– Hard to extract the rules ()

Fuzzy Logic

– Tolerance imprecision ()

– Membership/Rule defined ()

Genetic Algorithm

– Fitness Functions Unclear ()

Heuristics Search

– Model Required ()

Fuzzy Neural

– No model required ()

– Rule Extraction ()

Case-based Reasoning

– Cases Available ()

– Huge Case-Bases System ()

Data Mining

– Data Available ()

Rule Based

– Domain Rule available ()