The invention relates to automated control of a machine tool.
Tool vibrations may occur during machining of components by use of program-controlled machine tools. The tool vibrations may affect the machining accuracy and the finish quality of the component and may also reduce the life of the tool. For this reason, a machining control program may include to machining parameters selected to limit vibrations during machining.
This disclosure is directed to techniques for automated control of a machine tool. In some examples, a controller for a machine tool may monitor acoustic signals during machining to evaluate the quality of a machined component. The controller may modify a machining parameter of the machining of the component based on the monitored acoustic signals. For example, the controlled may select a modified machining parameter expected to reduce vibrations such as chatter resulting from machining resonance. The disclosed techniques may be applied to the machining of thin-walled components, which may be associated with relatively unpredictable vibrations modes (e.g., machining resonances) during a machining process.
In one example, this disclosure is directed to a method comprising sending, by a computing device, control signals to a machine tool to machine a component to form a feature in the component according to the control signals, monitoring, by the computing device, while machining the feature into the component with the machine tool, acoustic signals produced by the machining of the component by the machine tool, during the machining of the feature into the component, modifying, by the computing device, at least one machining parameter defined by the control signals based on the monitored acoustic signals, and continuing to send, by the computing device, the modified control signals to the machine tool to machine the feature into the component according to the modified machining parameter
In another example, this disclosure is directed to a system comprising a machine tool, and a computing device. The computing device is configured to send control signals to the machine tool for causing the machine tool to machine a component to form a feature in the component, monitor, while the machine tool machines the feature into the component, acoustic signals of the machine tool used to machine the component, during the machining of the feature into the component, modify at least one machining parameter defined by the control signals based on the monitored acoustic signals, and continue to send the modified control signals to the machine tool to machine the feature into the component according to the modified machining parameter.
In a further example, this disclosure is directed to a non-transitory computer-readable data storage medium having instructions stored thereon that, when executed by one or more processors of a computing device, cause the computing device to send control signals to a machine tool for causing the machine tool to machine a component to form a feature in the component, monitor, while the machine tool machines the feature into the component, acoustic signals of the machine tool used to machine the component, during the machining of the feature into the component, modify at least one machining parameter defined by the control signals based on the monitored acoustic signals, and continue to send the modified control signals to the machine tool to machine the feature into the component according to the modified machining parameter.
The details of one or more examples of this disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of this disclosure will be apparent from the description and drawings, and from the claims.
Vibrations during fabrication and resulting quality of machined features may vary even when a series of components is fabricated using the same equipment according to the same design and specifications resulting in variations in finish quality of machined surfaces among the series of components. For example, machining of thin-walled components may be associated with relatively unpredictable component vibration modes during a machining process. As described herein, machining parameters may be modified during machining of the feature based on monitoring acoustic signals from the machining of the feature by a machine tool.
Workpiece 24 is mounted to platform 38 in a manner that facilitates precise machining of workpiece 24 by machine tool 23. While the techniques disclosed herein may apply to workpieces of any materials, workpiece 24 may be metal, such as a thin wall metal.
Controller 30 represents a computing device configured to operate machine tool 23. In some examples, controller may be configured to adaptively machine workpiece 24 based on real-time or near real-time feedback of signals associated with the operation of machine tool 23, such as one or more of acoustic signals of spindle 26, vibration signals of component 24 via vibration sensor 17, element 28 vibration, and/or feed and/or rotational forces of machine tool 23. Controller 30 may further be configured to prevent harmonic excitation of element 28 and component 24 based on the signals, such as monitored acoustic signals of spindle 26 of machine tool 23 or generated by interaction of machine tool 23 and workpiece 24.
Control signals from controller 30 for causing machine tool 23 to machine workpiece or component 24 may be based on a predetermined design of the feature and the monitored signals such as monitored acoustic signals. Controller 30 is further configured to, during the machining of the feature into component 24, modify at least one machining parameter defined by the control signals based on the monitored acoustic signals. For example, controller 30 may operate to adjust the feed rate of spindle 26, rotational speed of spindle 26, machining depth of spindle 26, feed force of spindle 26, and/or rotational force of spindle 26 based on the monitored acoustic signals to prevent harmonic excitation (e.g., resonance) of element 28 and component 24.
In one particular example, controller 30 may select the at least one machining parameter to mitigate machining resonance or machining resonance induced chatter during the machining of component 24 by machine toot 23. For example, controller 30 may assess monitored acoustic signals of spindle 26 by evaluating overall maximum acoustic signals, variation between maximum and minimum acoustic signals, along with frequency of acoustic signals variation. In this manner, controller 30 may operate to automatically mitigate harmonic excitation (e.g., machining resonance) of element 28 and component 24 based on monitored acoustic signals of machine tool 23, and potentially other machining variables, during the machining of features in component 24. Controller 30 is further configured to continue to send the modified control signals to machine tool 23 to machine the feature into component 24 according to the modified machining parameters.
Acoustic sensor 15 may be a microphone, such as a directional microphone configured to detect on or more of audible signals, subsonic signals or ultrasonic signals. While acoustic sensor 15 is depicted as being located on platform 38, acoustic sensor 115 may be positioned in other places, such as on spindle 26 or a mechanical holding arm (not shown) for spindle 26. In the same or different examples, multiple acoustic sensors may be used to monitor an acoustic signal. For example, multiple signal inputs, such as microphones placed in different locations and timing signals from the machining, may be used to effectively filter background noise generated from the machining process. In some examples, noise filtering may include filtering ambient noises and noises associated with the operation of machine tool 23 when element 28 is not contacting component 24. In the same or different examples, noise filtering may include actively sensing for known or predicted resonance frequencies of component 24 and/or element 28, such as harmonic frequencies as discussed in further detail with respect to
System 20 is also shown with an optional vibration sensor 17. In some examples, controller 30 may monitor, while machining the feature into component 24 with machine tool 23, vibrations produced by the machining of component 24 by machine tool 23 via vibration signals. Controller 20 may modify at least one machining parameter defined by the control signals based on the monitored vibration signals, either in conjunction with or instead of monitored acoustic signals. For example, controller 30 may operate to adjust the teed rate of spindle 26, rotational speed of spindle 26, machining depth of spindle 26, feed force of spindle 26 and/or rotational force of spindle 26 based on the monitored vibration signals to prevent harmonic excitation of element 28 and component 24. In one particular example, controller 30 may select the at least one machining parameter to mitigate machining resonance or machining resonance induced chatter during the machining of component 24 by machine tool 23. Controller 30 is further configured to continue to send the modified control signals to machine tool 23 to machine the feature into component 24 according to the modified machining parameters.
In some particular examples, controller 30 may include multiple computing devices that combine to provide the functionality of controller 30 as described herein, For example, controller 30 may comprise a CNC controller that issues instructions to spindle 26 and positioning actuators of machine tool 23 as well as a separate computing device that monitors acoustic signals from machine tool 23 and actively adjusts the feed rate, depth and/or rotational speed of spindle 26 based on the monitored signals.
In some examples, such a computing device may represent a general purpose computer running software, Software suitable for actively controlling machining parameters includes Tool Monitor Adaptive Control (TMAC) software from Caron Engineering of Wells, Me., United States. In addition, software suitable for actively monitoring acoustic signals to detect machining resonance or machining resonance induced chatter includes Harmonizer software from BlueSwarf LLC of State College, Pa., United States.
In a specific example where component 24 is a thin-walled component, machine component 24 to form a feature in component 24 may include reducing a wall thickness of component 24. For example, component 24 may be a thin-walled component providing thicknesses of less than about 0.01 inches. In one particular example, component 24 may be a blade airfoil. As represented by
As shown in
As mentioned previously,
In order to mitigate the machining resonance or machining resonance induced chatter represented by
Actively mitigating machining resonance or machining resonance induced chatter may provide one or more advantages including, but not limited to, increased tooling life, improved surface finish and increased productivity resulting from active selection of machining parameters according to acoustic signals produced by the machining.
In general, blade 200 is a component of a mechanical system including, e.g., a gas turbine engine, In different examples, blade 200 may be a compressor blade that imparts kinetic energy into a fluid or a turbine blade that extracts kinetic energy from a moving fluid.
During operation of gas turbine engine 220, blade 200 rotates relative to blade track 222 in a direction indicated by arrow 230. In general, the power and efficiency of gas turbine engine 220 can be increased by reducing the gap blade track 222 and blade 200, e.g., to reduce or eliminate gas leakage around blade 200. Thus, gas turbine engine 220, in various examples, is configured to allow blade 200 to abrade into surface 224 of turbine substrate 226, thereby defining blade track 222, which creates a seal between blade track 222 and blade 200. The abrading action may create high thermal and shear stress forces at blade tip 214. In addition, occasional movement of blade tip 214 relative to turbine substrate 226 during the operation of gas turbine engine 222 may cause blade tip 214 to impinge on turbine substrate 226, creating high shear forces at blade tip 214.
To protect against the various forces acting on blade 200 and, in particular, blade tip 214, one or more protective layers may be provided on blade 200 and/or blade tip 214. For example, a tip coating 228, may be provided on blade tip 214 to improve different properties of an underlying blade surface including, e.g., wear, corrosion, hardness, and/or temperature resistance properties of an underlying blade surface. Additionally or alternatively, a protective coating may be applied to an entire airfoil 202, including blade tip 214, to improve different properties of an underlying blade surface. In some examples, airfoil 202 may receive a coating that reduces or substantially eliminates the effects of oxidation or corrosion on airfoil 202. Regardless of the specific number or specific type of coatings applied to blade 200, in some examples, blade 200 may benefit from the features and arrays of features, such as an array of thin film cooling holes, described in the disclosure.
An airfoil, such as blade 200, may include additional machined features, which may be machined in conjunction with the fabrication of thin film cooling holes to reduce the cycle time required to for the blade airfoil. For example, machining to produce a blade airfoil, such as blade 200, may include gating removal and/or throat machining at the leading edge of the blade airfoil. As another example, machining to produce a blade airfoil may include hole drilling along the trailing edge of the blade airfoil. As further examples, machining to produce a blade airfoil may also include slash face along fore and aft faces and/or tip cap finishing. Each of these machining processes may be implemented in combination with techniques to mitigate machining resonance or machining resonance induced chatter. In addition, more than one feature may potentially be machined simultaneously on blade airfoil to further reduce cycle time.
Controller 30 sends control signals machine tool 23 to machine component 24 to form a feature in component 24 according to the control signals (302). While machining the feature into component 24 with machine tool 23, controller 30 monitors acoustic signals produced by the machining of the component 24 by machine tool 23 via acoustic sensor 15 (304). For example, controller 34 may continuously evaluate the acoustic signals to determine whether there is increasing machining resonance or machining resonance induced chatter (306). Controller 30 modifies at least one machining parameter defined b the control signals based on the monitored acoustic signals (308). For example, controller 30 may operate to adjust the feed rate of spindle 26, rotational speed of spindle 26, machining depth of spindle 26, feed force of spindle 26 and/or rotational force of spindle 26 based on the monitored vibration signals to prevent harmonic excitation of element 28 and component 24. Controller 30 continues to send the modified control signals to machine tool 23 to machine the feature into component 24 according to the modified machining parameter (302).
In some examples, controller 30 may further monitor vibrations signals produced by the machining of the component 24 by machine tool 23 via vibration sensor 17. For example, controller 34 may continuously evaluate the vibrations and the acoustic signals to determine whether there is increasing machining resonance or machining resonance induced chatter. In such an example, modification of the machining parameter may be further based on the monitored vibrations.
In some examples, controller 30 may store an indication of the monitored acoustic signals, the monitored vibrations, and/or the modified machining parameters on a non-transitory computer-readable data storage medium of controller 30. Such information may he later retrieved to evaluate a quality of component 24, and/or the operation of machine tool 23 and controller 30.
The techniques described in this disclosure may be implemented, at least in part, in hardware, software, firmware, or any combination thereof For example, various aspects of the described techniques, including controller 30, may be implemented within one or more processors, including one or more microprocessors, digital signal processors (DSPs), application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or any other equivalent integrated or discrete logic circuitry, as well as any combinations of such components. The term “processor” or “processing circuitry” may generally refer to any of the foregoing logic circuitry, alone or in combination with other logic circuitry, or any other equivalent circuitry. A control unit including hardware may also perform one or more of the techniques of this disclosure.
Such hardware, software, and firmware may be implemented within the same device or within separate devices to support the various techniques described in this disclosure. In addition, any of the described units, modules or components may be implemented together or separately as discrete but interoperable logic devices. Depiction of different features as modules or units is intended to highlight different functional aspects and does not necessarily imply that such modules or units must be realized by separate hardware, firmware, or software components. Rather, functionality associated with one or more modules or units may be performed by separate hardware, firmware, or software components, or integrated within common or separate hardware, firmware, or software components.
The techniques described in this disclosure may also be embodied or encoded in a computer system-readable medium, such as a computer system-readable storage medium, containing instructions. Instructions embedded or encoded in a computer system-readable medium, including a computer system-readable storage medium, may cause one or more programmable processors, or other processors, to implement one or more of the techniques described herein, such as when instructions included or encoded in the computer system-readable medium are executed by the one or more processors. Computer system readable storage media may include random access memory (RAM), read only memory (ROM), programmable read only memory (PROM), erasable programmable read only memory (EPROM), electronically erasable programmable read only memory (EEPROM), flash memory, a hard disk, a compact disc ROM (CD-ROM), a floppy disk, a cassette, magnetic media, optical media, or other computer system readable media. In some examples, an article of manufacture may comprise one or more computer system-readable storage media.
Various examples of this disclosure have been described. These and other examples are within the scope of the following claims.
This application claims the benefit of U.S. Provisional Application No. 62/145,915 filed Apr. 10, 2015, which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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62145915 | Apr 2015 | US |