Method for determination of adaptive process monitoring limits in process planning in account of dimensional tolerances and prognosis quality

• Applicant: Professor Dr.-Ing. Berend Denkena
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 508102133

The objective of the proposed project is the investigation of a method for generating adaptive process monitoring limits in process planning, taking into account dimensional tolerances, critical process cases and determined prognosis quality for complete machining. To achieve this objective, a simulation-based calculation of monitoring limits is realized by using an NC code-based, efficient material removal simulation and process-unspecific current modeling. Afterwards, critical and non-critical process cases are identified by experimental investigations and a decision logic for adaptation individual monitoring limit is researched. To adjust the monitoring limits for non-critical processes, local cutting values are calculated by a detailed material removal simulation, systematic simulation errors are investigated and the modelling of process monitoring signals for different machining operations are explored. A process-specific empirical current modeling approach is investigated for critical process cases. If critical processes have fine tolerance, it will be investigated if a detailed material removal simulation is usable for certain critical processes and whether a numerical-empirical modeling is preferable to an empirical modeling. In the next step, a methodology for the adaptation of the simulation-based process monitoring limits will be elaborated, which take account defined dimensional tolerances, critical processes and determined prognosis quality of simulation and process signal models. Finally, the partial aspects will be combined and researched in an overall method.

• DFG Programme: Research Grants