This paper proposes an Optimized Feed Scheduling Strategy (OFSS). This strategy integrates the feed drive dynamics with the minimum-time trajectory planing to achieve the desired feed rate at the appropriate tool position along specified tool path. It optimizes the use of the feed drive capabilities and provides good tracking of the cutting geometry variations. The feed scheduling is applied to maintain near-constant cutting force magnitude. An integrated geometric and mechanistic force model is used to estimate the in-cut geometry and the cutting force. A methodology based on time series modeling and analysis is proposed to identify the low frequency feed drive dynamics. The resulting model is applied as an acceleration/deceleration processor (Acc/Dec) to relate the actual feed rate to the commanded feed rate specified in the G-Code file. The effectiveness of the OFSS is analyzed using ball end milling operations. Its performance in terms of productivity and machining safety is assessed based on comparison with other feed scheduling techniques where the trajectory planing does not consider the feed drive dynamics.

Machine tool

10.1115/imece2002-33613

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Citations (2)

Open-architecture controller for die and mold machining

T. Bailey Y. Ruget Allan D. Spence M.A. Elbestawi

This paper encompasses work at the McMaster University IMMRC which is ongoing in the combined research areas of open-architecture machine control (OAC) and advanced machining systems. In particular the paper describes technologies developed to schedule and monitor die and mold machining. These technologies are implemented on an OAC hardware/software platform supporting a full 3-axis CNC machining centre.

Electrical Discharge Machining

10.1109/acc.1995.529236

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Citations (9)

A Systems Framework for Platform Architecture Analysis

Rafael A. Araque T. Bailey Murilo W. Bonilha Jay Fletcher

This paper discusses a systems framework for platform architecture analysis. The framework considers architectural analysis at three levels; the individual product offerings within a product family, the platform(s) being leveraged across the family, and the evolution potential for the platform/product family. The framework is decomposed into elements that consider a systems perspective: function, form, concepts, interfaces, needs/goals, upstream and downstream influences, and timing/operation. An application of the framework to a transport refrigeration product family is presented as a case study. The results of this case study indicate that the framework is promising, and it continues to be developed and applied within UTC.

Architecture framework

10.1115/detc2004-57299

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Citations (3)

Generic Simulation Approach for Multi-Axis Machining: Part I—Modeling Methodology

Manufacturing engineering (2000)

T. Bailey M.A. Elbestawi Tahany El-Wardany P. Fitzpatrick

Abstract This paper presents a new methodology for analytically simulating multi axis machining of complex sculptured surfaces. A generalized approach is developed for representing an arbitrary cutting edge design, and the local surface topology of a complex sculptured surface. A NURBS curve is used to represent the cutting edge profile. This approach offers the advantages of representing an arbitrary cutting edge design in a generic way, as well as providing standardized techniques for manipulating the location and orientation of the cutting edge. The local surface topology of the part is defined as those surfaces generated by previous tool paths in the vicinity of the current tool position. The local surface topology of the part is represented without using a computationally expensive CAD system. A systematic prediction technique is then developed to determine the instantaneous tool/part interaction during machining. The methodology employed here determines cutting edge in-cut segments by determining the intersection between the NURBS curve representation of the cutting edge and the defined local surface topology. These in-cut segments are then utilized for predicting instantaneous chip load, static and dynamic cutting forces, and tool deflection. Part I of this paper details the modeling methodology and demonstrates the capabilites of the simulation for machining a complex surface. Part II details both the model calibration procedure and discusses a case study of process optimization through feed rate scheduling.

Cutting tool

Representation

10.1115/imece2000-1908

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Citations (3)

Identification of acceleration deceleration profile of feed drive systems in CNC machines

International Journal of Machine Tools and Manufacture (2003)

Nejah Tounsi T. Bailey M.A. Elbestawi

Jerk

Machine tool

Feed forward

Finite impulse response

Impulse response

Tachometer

10.1016/s0890-6955(02)00304-8

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Citations (41)

Generic mechanistic modeling for multi-axis machining

T. Bailey

Source

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Citations (6)

Generic Simulation Approach for Multi-Axis Machining, Part 2: Model Calibration and Feed Rate Scheduling

Journal of Manufacturing Science and Engineering (2002)

T. Bailey M.A. Elbestawi Tahany El-Wardany P. Fitzpatrick

This is the second part of a two-part paper presenting a new methodology for analytically simulating multi-axis machining of complex sculptured surfaces. The first section of this paper offers a detailed explanation of the model calibration procedure. A new methodology is presented for accurately determining the cutting force coefficients for multi-axis machining. The force model presented in Part 1 of this paper is reformulated so that the cutting force coefficients account for the effects of feed rate, cutting speed, and a complex cutting edge design. Experimental results are presented for the calibration procedure. Model verification tests were conducted with these cutting force coefficients. These tests demonstrate that the predicted forces are within 5% of experimentally measured forces. Simulated results are also shown for predicting dynamic cutting forces and static/dynamic tool deflection. The second section of the paper discusses how the modeling methodology can be applied for feed rate scheduling in an industrial application. A case study for process optimization of machining an airfoil-like surface is used for demonstration. Based on the predicted instantaneous chip load and/or a specified force constraint, feed rate scheduling is utilized to increase metal removal rate. The feed rate scheduling implementation results in a 30% reduction in machining time for the airfoil-like surface.

Machine tool

10.1115/1.1468864

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Citations (22)

Generic Simulation Approach for Multi-Axis Machining, Part 1: Modeling Methodology

Journal of Manufacturing Science and Engineering (2002)

T. Bailey M.A. Elbestawi Tahany El-Wardany P. Fitzpatrick

This paper presents a new methodology for analytically simulating multi-axis machining of complex sculptured surfaces. A generalized approach is developed for representing an arbitrary cutting edge design, and the local surface topology of a complex sculptured surface. A NURBS curve is used to represent the cutting edge profile. This approach offers the advantages of representing any arbitrary cutting edge design in a generic way, as well as providing standardized techniques for manipulating the location and orientation of the cutting edge. The local surface topology of the part is defined as those surfaces generated by previous tool paths in the vicinity of the current tool position. The local surface topology of the part is represented without using a computationally expensive CAD system. A systematic prediction technique is then developed to determine the instantaneous tool/part interaction during machining. The methodology employed here determines cutting edge in-cut segments by determining the intersection between the NURBS curve representation of the cutting edge and the defined local surface topology. These in-cut segments are then utilized for predicting instantaneous chip load, static and dynamic cutting forces, and tool deflection. Part 1 of this paper details the modeling methodology and demonstrates the capabilities of the simulation for machining a complex surface. Part 2 details both the model calibration procedure and discusses a case study of process optimization through feed rate scheduling.

Cutting tool

Representation

10.1115/1.1468863

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Citations (52)

Generic Simulation Approach for Multi-Axis Machining: Part II—Model Calibration and Feed Rate Scheduling

Manufacturing engineering (2000)

T. Bailey M.A. Elbestawi Tahany El-Wardany P. Fitzpatrick

Abstract This is the second part of a two-part paper presenting a new methodology for analytically simulating multi axis machining of complex sculptured surfaces. The first section of this paper offers a detailed explanation of the model calibration procedure. A new methodology is presented for accurately determining the cutting force coefficients for multi-axis machining. The force model presented in Part I of this paper is reformulated so that the cutting force coefficients account for the effects of feed rate, cutting speed, and a complex cutting edge design. Experimental results are presented for the calibration procedure. Model verification tests were conducted with these cutting force coefficients. These tests demonstrate that the predicted forces are within 5% of experimentally measured forces. Simulated results are also shown for predicting dynamic cutting forces and static/dynamic tool deflection. The second section of the paper discusses how the modeling methodology can be applied for feed rate scheduling in an industrial application. A case study for process optimization of machining an airfoil-like surface is used for demonstration. Based on the predicted instantaneous chip load and/or a specified force constraint, feed rate scheduling is utilized to increase metal removal rate. The feed rate scheduling implementation results in a 30% reduction in machining time for the airfoil-like surface.

Machine tool

10.1115/imece2000-1909

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Citations (2)