WO2007065959A1 - Method for monitoring burr formation in processes involving the drilling of parts - Google Patents
Method for monitoring burr formation in processes involving the drilling of parts Download PDFInfo
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- WO2007065959A1 WO2007065959A1 PCT/ES2005/000665 ES2005000665W WO2007065959A1 WO 2007065959 A1 WO2007065959 A1 WO 2007065959A1 ES 2005000665 W ES2005000665 W ES 2005000665W WO 2007065959 A1 WO2007065959 A1 WO 2007065959A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B35/00—Methods for boring or drilling, or for working essentially requiring the use of boring or drilling machines; Use of auxiliary equipment in connection with such methods
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0961—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring power, current or torque of a motor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2215/00—Details of workpieces
- B23B2215/04—Aircraft components
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2222/00—Materials of tools or workpieces composed of metals, alloys or metal matrices
- B23B2222/04—Aluminium
Definitions
- Drilling operations usually produce burrs on both the inlet and outlet surfaces. They are formed as a result of the plastic deformation, which largely depends on the ductility of the material. Burrs during drilling constitute an unavoidable obstacle in the automation of assembly processes due to the need for a deburring stage. Burrs are a source of dimensional errors and misalignments; they can cause short circuits in electrical components; reduce the fatigue life of riveted parts; and can act as initial cracking points. For these reasons, the reduction in the quality of drilling operations is a crucial problem, especially for the aeronautical and aerospace industries. In these small burrs are allowed, below a certain height that is between 100 and 150 microns.
- the method of the invention is characterized by being a method of monitoring the formation of burrs in parts drilling processes in which a drill head, the head motor regulator, is used, previously establishing a fixed process of drilling in which the value of the process variables is set under the production conditions and among them the value of one or more speeds of advance, in which in each process of drilling parts: a) the admissible height is set burr -A- b) the signal associated with the torque from the head motor regulator is captured, the "cutting zone” comprised between the point where the drill bit touches the input surface in the material is determined in said signal until The drill is again outside the hole after the recoil of the head; c) several zones are defined within the "cutting zone”: the "exit point” is established as the point at which the tip of the drill bit crosses the exit surface of the hole; the "exit zone” is established as the zone immediately after the "exit point”; the "reference level” (RL) is calculated as the average value reached by the signal in the area in which the drill bit crosses
- N Minimun / RL e) the relative minimum value is calculated for the set process and a comparison relative minimum value (Nc) is established with a pre-established tolerance; f) the signal from the head motor regulator is captured during the industrial drilling process in production, the relative minimum value (N) for each hole is calculated in the "cutting zone", deciding that the height of the burr is admissible if said value (N) is less than the value of the relative minimum of comparison (Nc) with the pre-established tolerance: N ⁇ Nc.
- the relative maximum value (M) is defined as the quotient between the maximum value (Maximun) reached by the signal in the "pre-departure zone” and the “reference level” (RL):
- M Maximun / RL b) the relative maximum value is calculated for the fixed process and a comparison relative maximum value (Mc) is established with a pre-established tolerance; c) the signal from the head motor regulator is captured during the industrial drilling process in production, calculated in
- the "cutting zone” is the relative maximum value (M) for each hole, deciding that the height of the burr is admissible if said value (M) is less than the value of the relative minimum of comparison (Mc) with the pre-established tolerance: M ⁇ Mc. It is also characterized because: a) a neural network is designed and trained that uses the magnitude N defined in 1 d) as an input, the level of burr will be established as an output of the network, which may adopt different defined burr levels for the interest of the user; b) the signal from the head motor regulator is captured during the industrial drilling processes in production, the value of the magnitudes used as inputs of the neural network is calculated for each hole, the output of the neural network will indicate the level burr.
- a neural network is designed and trained that uses the magnitudes W, H, S defined in 2d as inputs, the level of burr will be established as an output of the network, which may adopt different levels of burr defined by user interest; b) the signal from the head motor regulator is captured during the industrial drilling processes in production, the value of the magnitudes used as inputs of the neural network is calculated for each hole, the output of the neural network will indicate the level burr.
- a neural network is designed and trained that uses the magnitude M defined in 3d as an input), the level of burr will be established as an output of the network, which may adopt different levels of burr defined by the interest of the user; b) the signal from the head motor regulator is captured during the industrial drilling processes in production, the value of the magnitudes used as inputs of the neural network is calculated for each hole, the output of the neural network will indicate the level burr.
- Figure 1 is a representation in torque / time coordinates of the complete signal of the regulator associated with the spindle motor.
- Figure 2 are representations in torque / penetration coordinates (mm).
- Figure 3 is a representation in torque / time coordinates of an estimate of the point of entry of the drill bit into the material as the intersection between two lines.
- Figure 4 is a representation in torque / time coordinates of the cutting zone with the pre-exit zone, exit zone, post-exit zone, exit point and reference level: a) with a forward speed b) with two forward speeds.
- Figure 5 is a representation of Figure 4b with the five magnitudes sensitive or fundamental to burr formation in the specific case of using two forward speeds.
- Figure 6 are four representations (a), (b), (c), (d) of torque / penetration coordinates (mm) of signals with different burr level changing the advance speed mm / rev. A non-limiting practical embodiment of the present invention is described below.
- test material has been aluminum in its alloys used in aeronautics. Signal acquisition system
- the analog output of the regulator corresponding to the spindle motor has been captured, which is associated with the torque. Internally it is a current signal in the motor loop, but externally it is presented as a voltage signal in a range between -1 0 and + 1 0 V. It is convenient to adjust the full scale to use the resolution of the measurement to the maximum.
- the signal from the spindle motor is an indirect measure of torque, which compared to direct measurements has the advantage of not needing additional devices and facilitating the implementation of the monitoring method in the machine's own CNC control.
- Figure 1 shows a signal captured during an example drilling test in which a single hole was made.
- the first range of large oscillations corresponds to the "Acceleration zone” of the head.
- the torque decreases almost to zero.
- the "Approach Zone” of the tool begins until the work material.
- the measured torque grows in the "Cutting zone", comprised between the point where the drill bit touches the input surface in the material until the drill bit is out of the hole again after the head recoils.
- This area includes both the area in which the drill bit passes through the material in the direction and direction of drilling, and the backward travel of the drill bit in the reverse direction until the tip of the tool returns to the entrance surface of the hole.
- the “Deceleration zone” represented in the negative plane.
- the signal from the regulator can be rescaled in torque units with the appropriate calibration. This obviously depends on the power curve of the particular machine. In our particular case, the transformation is reduced to the following equation:
- Figure 2 shows two examples of filtered signals, one in Fourier space with a filter.
- the "exit zone” is established as the zone immediately after the "exit point", which comprises from when the tip of the drill bit touches the exit surface of the hole until it begins to recede;
- the "Reference level” (RL) is defined as the average value reached by the signal in the area in which the drill bit passes through the internal section of the hole in which it is approximately constant for fixed process conditions.
- Figure 4a shows an example in which a single forward speed has been used throughout the entire hole, while in Figure 4b two different forward speeds have been used.
- the reference level is calculated as the average of the value of the signal in the central part of the hole, while in the second case it is calculated as the average in the section corresponding to the second speed. It would be calculated in a similar way if 3 speeds were used along the length of the hole, only calculated in the section corresponding to the last speed.
- a fixed drilling process is established in which the value of the process variables is set under the conditions of production that interest the user (machine, tool, process parameters, etc.).
- the fundamental parameter is the value of the relative minimum (N).
- a comparison value can be established for each of the attributes chosen by different standard methods: minimum that satisfies the requirements, linear adjustment for least squares, fuzzy logic methods, etc. The burr will be acceptable if it is successively fulfilled: N ⁇ Nc , M ⁇ Mc, W ⁇ Wc, H ⁇ Ho, S> Sc, (if all attributes are not chosen, the same order is followed for the chosen ones).
- the acceptable burr height limit has been set at 1 27 microns (Hb).
- the signals with a sampling frequency of 5000 Hz have been captured.
- the signal has been represented as a function of the depth of the hole, that is, the time has been converted into depth (mm), taking the point where the drill bit is zero. touch the material.
- TN 16.97 (N m) is the nominal torque of the machine equivalent to 5 (V) and VT is the measured voltage of the head regulator. •
- the established comparison values are:
- the first method of monitoring burrs during drilling has been developed.
- the algorithm is based on the analysis of the signals coming from the spindle motor regulator. This facilitates and lowers the implementation of the method in the control to use it automatically.
- the reliability of this method is above 92% for an extensive parameter range under high speed dry drilling conditions for aluminum alloys, for example, Al 7075-T6.
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- Mechanical Engineering (AREA)
- Numerical Control (AREA)
- Drilling And Boring (AREA)
Abstract
Description
"MÉTODO DE MON1TORIZACIÓN DE LA FORMACIÓN DE REBABAS EN LOS PROCESOS DE TALADRADO DE PIEZAS" "METHOD OF MONITORING THE FORMATION OF BURS IN THE PROCESSES OF DRILLING OF PIECES"
D E S C R I P C I Ó N D E S C R I P C I Ó N
Las operaciones de taladrado producen habitualmente rebabas tanto en Ia superficie de entrada como en Ia de salida. Se forman como resultado de Ia deformación plástica, que depende en gran medida de Ia ductilidad del material. Las rebabas durante el taladrado constituyen un obstáculo ineludible en Ia automatización de los procesos de ensamblado por Ia necesidad de una etapa de desbarbado. Las rebabas son una fuente de errores dimensionales y desalineamientos; pueden causar cortocircuitos en componentes eléctricos; reducen el tiempo de vida a fatiga de las piezas remachadas; y pueden actuar como puntos iniciales de grietas. Por estas razones, Ia reducción en Ia calidad de las operaciones de taladrado es un problema crucial, en especial para las industrias aeronáutica y aeroespacial. En éstas se permiten rebabas pequeñas, por debajo de una cierta altura que se encuentra entre 100 y 150 mieras. Drilling operations usually produce burrs on both the inlet and outlet surfaces. They are formed as a result of the plastic deformation, which largely depends on the ductility of the material. Burrs during drilling constitute an unavoidable obstacle in the automation of assembly processes due to the need for a deburring stage. Burrs are a source of dimensional errors and misalignments; they can cause short circuits in electrical components; reduce the fatigue life of riveted parts; and can act as initial cracking points. For these reasons, the reduction in the quality of drilling operations is a crucial problem, especially for the aeronautical and aerospace industries. In these small burrs are allowed, below a certain height that is between 100 and 150 microns.
Por estas razones, en Ia mayoría de los casos no se puede evitar Ia fase de desbarbado después del taladrado. En el ensamblado aeronáutico, por ejemplo, los componentes a unir se taladran juntosFor these reasons, in most cases the deburring phase cannot be avoided after drilling. In aeronautical assembly, for example, the components to be joined are drilled together
(multicapa), se separan a continuación para eliminar las rebabas(multilayer), separated below to remove burrs
(desbarbado) y finalmente se remachan. El proceso de desbarbado supone un trabajo adicional que constituye un 30% del coste total en operaciones de precisión. La mayoría de los problemas están asociados a Ia rebaba a Ia salida, ya que es mucho más grande que a Ia entrada. Por esta razón,(deburred) and finally riveted. The deburring process involves additional work that constitutes 30% of the total cost in precision operations. Most of the problems are associated with the burr at the outlet, since it is much larger than at the inlet. For this reason,
Ia mayor parte de Ia investigación sobre este tema, y en particular este invento se ha centrado en desarrollar estrategias para minimizar Ia rebaba a Ia salida del material. Most of the research on this subject, and in particular this invention has focused on developing strategies to minimize the burr at the exit of the material.
Por un lado, diversos grupos de investigación han optimizado Ia geometría de Ia herramienta (broca) para que se reduzca en Io posible las dimensiones de Ia rebaba a Ia salida. Por otro lado, también existe una extensa investigación orientada a Ia optimización de los parámetros del proceso para minimizar Ia rebaba. La mayor parte de los trabajos son experimentales y se han elaborado por ejemplo cartas de control para tener mapas con los que poder estimar Ia altura o Ia forma de Ia rebaba en función de los parámetros del proceso. También se han desarrollado modelos de elementos finitos para conocer mejor el proceso de formación de rebaba y predecir el resultado. On the one hand, various research groups have optimized the geometry of the tool (drill) so that the dimensions of the burr at the outlet are reduced as far as possible. On the other hand, there is also extensive research aimed at optimizing process parameters to minimize burr. Most of the work is experimental and, for example, control charts have been prepared to have maps with which to estimate the height or shape of the burr depending on the process parameters. Finite element models have also been developed to better understand the burr formation process and to predict the outcome.
Los resultados de estos trabajos son de gran importancia para Ia optimización del proceso de taladrado, pero no son capaces de asegurar Ia calidad de los agujeros, ya que no tienen en cuenta por ejemplo el desgaste de Ia herramienta que influye en Ia formación de rebabas o las componentes estocásticas que no se pueden controlar. Por estas razones, incluso estableciendo un proceso industrial en condiciones óptimas en cuanto a herramienta utilizada y a parámetros de proceso, existe siempre un porcentaje no despreciable de agujeros que presentan una altura de rebaba por encima de los requerimientos del cliente. En los sectores aeronáutico y aeroespacial en los que Ia calidad de los componentes mecanizados es de vital importancia para asegurar Ia seguridad de sus productos, los requerimientos en cuanto a Ia máxima altura de rebaba permitida son muy rigurosos. Por ello, no se admiten agujeros con rebaba aunque sólo constituyan un bajo porcentaje y Ia fase de desbarbado no puede eliminarse. Además, como no se sabe qué agujeros tienen rebaba se desbarban todos ellos, aumentando el coste de Ia operación sin realmente obtener beneficio de todo el tiempo invertido. En este invento desarrollamos el primer método para Ia monitorización on-line de rebabas enfocado a condiciones de alta velocidad, de gran interés en aeronáutica. Con él se puede evitar el desbarbado de todos los agujeros, reduciendo esta operación a aquellos agujeros que incumplan los requerimientos del cliente. Métodos para Ia monitorización del desgaste de herramienta han sido extensamente investigados, pero no existe ningún método aplicado a Ia altura de Ia rebaba. The results of these works are of great importance for the optimization of the drilling process, but are not capable of ensuring the quality of the holes, since they do not take into account, for example, the wear of the tool that influences the formation of burrs or stochastic components that cannot be controlled. For these reasons, even when establishing an industrial process under optimal conditions in terms of the tool used and the process parameters, there is always a non-negligible percentage of holes that have a burr height above the customer's requirements. In the aeronautical and aerospace sectors in which the quality of the machined components is of vital importance to ensure the safety of your products, the requirements regarding the maximum permitted burr height are very rigorous. For this reason, burr holes are not allowed even though they only constitute a low percentage and the deburring phase cannot be eliminated. Furthermore, since it is not known which holes have burrs, all of them are deburred, increasing the cost of the operation without actually obtaining a benefit from all the time invested. In this invention we develop the first method for online monitoring of burrs focused on high-speed conditions, of great interest in aeronautics. With it you can avoid the deburring of all holes, reducing this operation to those holes that do not meet customer requirements. Methods for monitoring tool wear have been extensively investigated, but there is no method applied to the height of the burr.
En concreto, el método del invento se caracteriza por ser un método de monitorización de Ia formación de rebabas en los procesos de taladrado de piezas en el que se utiliza un cabezal porta-broca, el regulador del motor del cabezal, estableciéndose previamente un proceso fijado de taladrado en el que se fija el valor de las variables del proceso en las condiciones de producción y entre ellas el valor de una o varias velocidades de avance, en el que en cada proceso de taladrado de piezas: a) se fija Ia altura admisible de rebaba; -A- b) se capta Ia señal asociada al par procedente del regulador del motor del cabezal, se determina en dicha señal Ia "zona de corte" comprendida entre el punto en el que Ia broca toca Ia superficie de entrada en el material hasta que Ia broca se encuentra de nuevo fuera del agujero después del retroceso del cabezal; c) se definen varias zonas dentro de Ia "zona de corte": se establece el "punto de salida" como el punto en el que Ia punta de Ia broca atraviesa Ia superficie de salida del agujero; se establece Ia "zona de salida" como Ia zona inmediatamente posterior al "punto de salida"; se calcula el "nivel de referencia" (RL) como el valor medio alcanzado por Ia señal en Ia zona en Ia que Ia broca atraviesa el tramo interno del agujero en el tramo correspondiente a Ia última velocidad de avance empleada; d) se define el valor de mínimo relativo (N) como el cociente entre el valor mínimo (Minimun) alcanzado por una señal en Ia "zona de salida" y el "nivel de referencia" (RL) : Specifically, the method of the invention is characterized by being a method of monitoring the formation of burrs in parts drilling processes in which a drill head, the head motor regulator, is used, previously establishing a fixed process of drilling in which the value of the process variables is set under the production conditions and among them the value of one or more speeds of advance, in which in each process of drilling parts: a) the admissible height is set burr -A- b) the signal associated with the torque from the head motor regulator is captured, the "cutting zone" comprised between the point where the drill bit touches the input surface in the material is determined in said signal until The drill is again outside the hole after the recoil of the head; c) several zones are defined within the "cutting zone": the "exit point" is established as the point at which the tip of the drill bit crosses the exit surface of the hole; the "exit zone" is established as the zone immediately after the "exit point"; the "reference level" (RL) is calculated as the average value reached by the signal in the area in which the drill bit crosses the internal section of the hole in the section corresponding to the last forward speed used; d) the relative minimum value (N) is defined as the quotient between the minimum value (Minimun) reached by a signal in the "output zone" and the "reference level" (RL):
N = Minimun / RL e) se calcula para el proceso fijado el valor de mínimo relativo y se establece un valor de mínimo relativo de comparación (Nc) con una tolerancia preestablecida; f) se capta Ia señal del regulador del motor del cabezal durante el proceso de taladrado industrial en producción, se calcula en Ia "zona de corte" el valor de mínimo relativo (N) para cada agujero, decidiéndose que Ia altura de Ia rebaba es admisible si dicho valor (N) es inferior al valor del mínimo relativo de comparación (Nc) con Ia tolerancia preestablecida: N < Nc. También se caracteriza porque: a) se definen tres magnitudes fundamentales: ai) el valor de anchura (W) de las perturbaciones cuya altura está por encima de un valor preestablecido (que denotaremos HP) que pudieran aparecer en Ia "zona post-salida"; a2) el valor máximo de altura (H) de las perturbaciones que pudieran aparecer en Ia "zona post-salida"; a3) el valor de pendiente (S) calculada en Ia "zona de salida"; b) se calculan para el proceso fijado los valores de anchura, máximo de altura y pendiente (W, H, S), se fija un valor HP y se establece un valor de comparación para cada una de las magnitudes (Wc, Hc, Sc) con una tolerancia preestablecida; c) se capta Ia señal del regulador del motor del cabezal durante el proceso de taladrado industrial en producción, se calcula en Ia "zona de corte" el valor de anchura, máximo de* altura y pendiente (W, H, S) para cada agujero, decidiéndose que Ia altura de Ia rebaba es admisible si se cumple sucesivamente con Ia tolerancia preestablecida: N = Minimun / RL e) the relative minimum value is calculated for the set process and a comparison relative minimum value (Nc) is established with a pre-established tolerance; f) the signal from the head motor regulator is captured during the industrial drilling process in production, the relative minimum value (N) for each hole is calculated in the "cutting zone", deciding that the height of the burr is admissible if said value (N) is less than the value of the relative minimum of comparison (Nc) with the pre-established tolerance: N <Nc. It is also characterized because: a) three fundamental quantities are defined: ai) the width value (W) of the disturbances whose height is above a pre-established value (which we will denote HP) that could appear in the "post-exit zone"; a2) the maximum height value (H) of the disturbances that may appear in the "post-exit zone"; a3) the slope value (S) calculated in the "exit zone"; b) the width, maximum height and slope values (W, H, S) are calculated for the fixed process, an HP value is set and a comparison value is established for each of the quantities (Wc, Hc, Sc ) with a pre-established tolerance; c) the signal of the head motor regulator is captured during the industrial drilling process in production, the value of width, maximum of * height and slope (W, H, S) is calculated in each "cutting zone" for each hole, deciding that the height of the burr is admissible if the preset tolerance is successively met:
También se caracteriza porque: a) se define el valor de máximo relativo (M) como el cociente entre el valor máximo (Maximun) alcanzado por Ia señal en Ia "zona pre-salida" y el "nivel de referencia" (RL) : It is also characterized because: a) the relative maximum value (M) is defined as the quotient between the maximum value (Maximun) reached by the signal in the "pre-departure zone" and the "reference level" (RL):
M = Maximun / RL b) se calcula para el proceso fijado el valor de máximo relativo y se establece un valor de máximo relativo de comparación (Mc) con una tolerancia preestablecida; c) se capta Ia señal del regulador del motor del cabezal durante el proceso de taladrado industrial en producción, se calcula enM = Maximun / RL b) the relative maximum value is calculated for the fixed process and a comparison relative maximum value (Mc) is established with a pre-established tolerance; c) the signal from the head motor regulator is captured during the industrial drilling process in production, calculated in
Ia "zona de corte" el valor de máximo relativo (M) para cada agujero, decidiéndose que Ia altura de Ia rebaba es admisible si dicho valor (M) es inferior al valor del mínimo relativo de comparación (Mc) con Ia tolerancia preestablecida: M < Mc. También se caracteriza porque: a) se diseña y se entrena una red neuronal que utilice como una entrada Ia magnitud N definida en 1 d), se establecerá como una salida de Ia red el nivel de rebaba, que podrá adoptar distintos niveles de rebaba definidos por el interés del usuario; b) se capta Ia señal del regulador del motor del cabezal durante los procesos de taladrado industrial en producción, se calcula para cada agujero el valor de las magnitudes que se utilizan como entradas de Ia red neuronal, Ia salida de Ia red neuronal indicará el nivel de rebaba. También se caracteriza porque: a) se diseña y se entrena una red neuronal que utilice como entradas las magnitudes W, H, S definidas en 2d), se establecerá como una salida de Ia red el nivel de rebaba, que podrá adoptar distintos niveles de rebaba definidos por el interés del usuario; b) se capta Ia señal del regulador del motor del cabezal durante los procesos de taladrado industrial en producción, se calcula para cada agujero el valor de las magnitudes que se utilizan como entradas de Ia red neuronal, Ia salida de Ia red neuronal indicará el nivel de rebaba. The "cutting zone" is the relative maximum value (M) for each hole, deciding that the height of the burr is admissible if said value (M) is less than the value of the relative minimum of comparison (Mc) with the pre-established tolerance: M <Mc. It is also characterized because: a) a neural network is designed and trained that uses the magnitude N defined in 1 d) as an input, the level of burr will be established as an output of the network, which may adopt different defined burr levels for the interest of the user; b) the signal from the head motor regulator is captured during the industrial drilling processes in production, the value of the magnitudes used as inputs of the neural network is calculated for each hole, the output of the neural network will indicate the level burr. It is also characterized because: a) a neural network is designed and trained that uses the magnitudes W, H, S defined in 2d as inputs, the level of burr will be established as an output of the network, which may adopt different levels of burr defined by user interest; b) the signal from the head motor regulator is captured during the industrial drilling processes in production, the value of the magnitudes used as inputs of the neural network is calculated for each hole, the output of the neural network will indicate the level burr.
También se caracteriza porque: a) se diseña y se entrena una red neuronal que utilice como una entrada Ia magnitud M definida en 3d), se establecerá como una salida de Ia red el nivel de rebaba, que podrá adoptar distintos niveles de rebaba definidos por el interés del usuario; b) se capta Ia señal del regulador del motor del cabezal durante los procesos de taladrado industrial en producción, se calcula para cada agujero el valor de las magnitudes que se utilizan como entradas de Ia red neuronal, Ia salida de Ia red neuronal indicará el nivel de rebaba. It is also characterized because: a) a neural network is designed and trained that uses the magnitude M defined in 3d as an input), the level of burr will be established as an output of the network, which may adopt different levels of burr defined by the interest of the user; b) the signal from the head motor regulator is captured during the industrial drilling processes in production, the value of the magnitudes used as inputs of the neural network is calculated for each hole, the output of the neural network will indicate the level burr.
Para comprender mejor el objeto de Ia presente invención, se representa en los planos una forma preferente de realización práctica, susceptible de cambios accesorios que no desvirtúen su fundamento. In order to better understand the object of the present invention, a preferred form of practical embodiment is shown in the drawings, susceptible to accessory changes that do not detract from its basis.
La figura 1 es una representación en coordenadas par/tiempo de Ia señal completa del regulador asociado al motor del cabezal. Figure 1 is a representation in torque / time coordinates of the complete signal of the regulator associated with the spindle motor.
La figura 2 son representaciones en coordenadas par/penetración (mm). (a) Zona de corte de una señal antes y después de un filtrado en el espacio de Fourier. (b) Zona de corte de una señal antes y después de un filtrado utilizando Wavelets. La figura 3 es una representación en coordenadas par/tiempo de una estimación del punto de entrada de Ia broca en el material como Ia intersección entre dos rectas. Figure 2 are representations in torque / penetration coordinates (mm). (a) Cut-off zone of a signal before and after filtering in Fourier space. (b) Cut zone of a signal before and after filtering using Wavelets. Figure 3 is a representation in torque / time coordinates of an estimate of the point of entry of the drill bit into the material as the intersection between two lines.
La figura 4 es una representación en coordenadas par/tiempo de Ia zona de corte con Ia zona de presalida, zona de salida, zona de post-salida, punto de salida y nivel de referencia: a) con una velocidad de avance b) con dos velocidades de avance. Figure 4 is a representation in torque / time coordinates of the cutting zone with the pre-exit zone, exit zone, post-exit zone, exit point and reference level: a) with a forward speed b) with two forward speeds.
La figura 5 es una representación de Ia figura 4b con las cinco magnitudes sensibles o fundamentales a Ia formación de rebaba en el caso concreto de utilizar dos velocidades de avance. Figure 5 is a representation of Figure 4b with the five magnitudes sensitive or fundamental to burr formation in the specific case of using two forward speeds.
La figura 6 son cuatro representaciones (a), (b), (c), (d) de coordenadas par/penetración (mm) de señales con diferente nivel de rebaba cambiando Ia velocidad de avance mm/rev. Se describe a continuación un ejemplo de realización práctica, no limitativa, del presente invento. Figure 6 are four representations (a), (b), (c), (d) of torque / penetration coordinates (mm) of signals with different burr level changing the advance speed mm / rev. A non-limiting practical embodiment of the present invention is described below.
Punto de partida Point
En un proceso industrial de taladrado Ia mayor parte de las condiciones de trabajo están fijadas. Tanto Ia herramienta, como el material de trabajo, como las dimensiones del agujero están bien definidas. Además, los parámetros del proceso suelen ser también fijos y están determinados por Ia velocidad de corte (giro del cabezal) y Ia velocidad de avance. Partimos de una situación así para aplicar el método de monitorización de rebabas: herramienta, material y dimensiones del agujero fijados, y Ia velocidad de corte y de avance definidas en un intervalo estrecho. En nuestro caso se ha utilizado un centro de mecanizado de alta velocidad de tres ejes, motores lineales y control Fidia. Sus especificaciones son: In an industrial drilling process, most of the working conditions are fixed. Both the tool, as the work material, and the dimensions of the hole are well defined. Furthermore, the process parameters are also usually fixed and are determined by the cutting speed (head rotation) and the forward speed. We start from a situation like this to apply the burr monitoring method: tool, material and fixed hole dimensions, and the cutting and advance speed defined in a narrow interval. In our case, a three-axis high-speed machining center, linear motors and Fidia control have been used. Its specifications are:
N: 24000 rpm N: 24000 rpm
Avance: 1 20 m /min Aceleración: 2g m/s2 Progress: 1 20 m / min Acceleration: 2g m / s2
Potencia nominal: 27 kW Nominal power: 27 kW
Par nominal: 1 6.97 Nm Nominal torque: 1 6.97 Nm
El material de ensayo ha sido aluminio en sus aleaciones utilizadas en aeronáutica. Sistema de adquisición de señales The test material has been aluminum in its alloys used in aeronautics. Signal acquisition system
Durante los ensayos de taladrado se ha capturado Ia salida analógica del regulador correspondiente al motor del cabezal, que está asociada al par (torque). Internamente es una señal de corriente en el bucle del motor, pero externamente se presenta como señal de voltaje en un rango entre -1 0 y + 1 0 V. Conviene ajustar el fondo de escala para utilizar al máximo Ia resolución de Ia medida. During the drilling tests, the analog output of the regulator corresponding to the spindle motor has been captured, which is associated with the torque. Internally it is a current signal in the motor loop, but externally it is presented as a voltage signal in a range between -1 0 and + 1 0 V. It is convenient to adjust the full scale to use the resolution of the measurement to the maximum.
La señal del motor del cabezal es una medida indirecta del par (torque), que frente a las medidas directas presenta Ia ventaja de no necesitar aparatos adicionales y de facilitar la implementación del método de monitorización en el propio control CNC de Ia máquina. The signal from the spindle motor is an indirect measure of torque, which compared to direct measurements has the advantage of not needing additional devices and facilitating the implementation of the monitoring method in the machine's own CNC control.
En Ia Figura 1 se muestra una señal capturada durante un ensayo de taladrado a modo de ejemplo en el que se realizó un sólo agujero. Se distinguen claramente cuatro zonas diferentes. El primer rango de grandes oscilaciones corresponde a Ia "Zona de aceleración" del cabezal. Una vez alcanzada Ia velocidad de corte impuesta, el par decrece casi hasta cero. Entonces comienza Ia "Zona de aproximación" de Ia herramienta hasta el material de trabajo. El par medido crece en Ia "Zona de corte", comprendida entre el punto en el que Ia broca toca Ia superficie de entrada en el material hasta que Ia broca se encuentra de nuevo fuera del agujero después del retroceso del cabezal. Esta zona incluye tanto Ia zona en Ia que Ia broca atraviesa el material en dirección y sentido del taladrado, como el recorrido de retroceso de Ia broca en sentido inverso hasta que Ia punta de Ia herramienta vuelve a Ia superficie de entrada del agujero. Finalmente se tiene Ia "Zona de deceleración", representado en el plano negativo. Como resultado de los ensayos efectuados hemos llegado a Ia conclusión que sólo Ia Zona de corte propiamente dicha contiene información relevante para Ia monitorización de las rebabas. Figure 1 shows a signal captured during an example drilling test in which a single hole was made. Four different zones are clearly distinguished. The first range of large oscillations corresponds to the "Acceleration zone" of the head. Once the imposed cutting speed is reached, the torque decreases almost to zero. Then the "Approach Zone" of the tool begins until the work material. The measured torque grows in the "Cutting zone", comprised between the point where the drill bit touches the input surface in the material until the drill bit is out of the hole again after the head recoils. This area includes both the area in which the drill bit passes through the material in the direction and direction of drilling, and the backward travel of the drill bit in the reverse direction until the tip of the tool returns to the entrance surface of the hole. Finally, there is the "Deceleration zone", represented in the negative plane. As a result of the tests carried out, we have reached the conclusion that only the cutting area itself contains relevant information for monitoring burrs.
La señal procedente del regulador se puede reescalar en unidades de par con Ia apropiada calibración. Esto depende obviamente de Ia curva de potencia de Ia máquina particular. En nuestro caso particular Ia transformación se reduce a Ia siguiente ecuación: The signal from the regulator can be rescaled in torque units with the appropriate calibration. This obviously depends on the power curve of the particular machine. In our particular case, the transformation is reduced to the following equation:
5[V) donde TN = 1 6.97 N m es el par nominal que equivale a 5 V. 5 [V) where TN = 1 6.97 N m is the nominal torque that equals 5 V.
Además por comodidad y para entender mejor el proceso, resulta útil representar Ia señal en función del recorrido de Ia herramienta (sin tener en cuenta si es hacia adelante o hacia atrás). Bien se puede realizar una transformación de tiempo a longitud a partir de las velocidades de avance del carro Z, o bien capturando Ia señal propia del control asociada a Ia posición del carro Z. Lo más útil es considerar el cero de Z cuando Ia punta de Ia broca toca Ia superficie de entrada del material. Sistema de monitorización Furthermore, for convenience and to better understand the process, it is useful to represent the signal depending on the path of the tool (regardless of whether it is forward or backward). Either a transformation from time to length can be made from the advance speeds of carriage Z, or by capturing the control signal associated with the position of carriage Z. The most useful thing is to consider the zero of Z when the tip of The bit touches the input surface of the material. Monitoring system
De los ensayos efectuados se obtiene como resultado básico que algunas magnitudes de Ia señal en Ia zona de corte dan información relevante del tamaño de rebaba originado, por Io que Ia esencia el invento reside en Ia monitorización del proceso en base a Ia cuantificación de dichas magnitudes. a) Procesado de Ia señal From the tests carried out, it is obtained as a basic result that some magnitudes of the signal in the cutting area give relevant information on the size of the burr caused, so that the essence of the invention resides in the monitoring of the process based on the quantification of said magnitudes. . a) Signal processing
Antes de calcular las magnitudes/atributos que nos interesan de Ia señal capturada resulta imprescindible filtrar el ruido y las frecuencias que enmascaran Ia información relevante. La información que se necesita para el sistema de monitorización está contenida en Ia envolvente de Ia señal en Ia "Zona de corte". Before calculating the magnitudes / attributes that interest us of the captured signal, it is essential to filter the noise and the frequencies that mask the relevant information. The information needed for the monitoring system is contained in the signal envelope in the "Cut zone".
Para esta tarea se puede utilizar el filtrado habitualThe usual filtering can be used for this task
(aplicación de ventana y filtro) o bien utilizar un método más avanzado como Ia transformada Wavelet. En Ia Figura 2 se muestran dos ejemplos de señales filtradas, una en el espacio de Fourier con un filtro(window and filter application) or use a more advanced method such as the Wavelet transform. Figure 2 shows two examples of filtered signals, one in Fourier space with a filter.
Butterworth y Ia segunda mediante Wavelets Daubechies. b) Cálculo de las magnitudes/atributos sensibles a Ia rebaba Butterworth and the second by Wavelets Daubechies. b) Calculation of the magnitudes / attributes sensitive to the burr
Una vez que se ha filtrado Ia señal, se analiza Ia "Zona de corte" de cada una de las señales en el dominio del tiempo, concretamente Ia parte alrededor de Ia salida de Ia herramienta, ya que en ese tramo se forma Ia rebaba. Para localizar ese tramo se pueden utilizar diferentes estrategias. La más sencilla es a partir de Ia posición del carro Z: bastaría tomar el cero sobre Ia superficie de entrada; se analizaría el rango entorno a Ia Z correspondiente al espesor del material. En el caso de que no se disponga de Ia posición del carro Z de forma directa se puede proceder de Ia siguiente manera (Figura 3) : Once the signal has been filtered, the "Cut zone" of each of the signals in the time domain, specifically the part around the tool outlet, is analyzed, since in that section the burr is formed. Different strategies can be used to locate this section. The simplest is from the position of carriage Z: it would suffice to take the zero on the input surface; the range around Z corresponding to the thickness of the material would be analyzed. In the event that the position of carriage Z is not available directly, the following procedure can be followed (Figure 3):
• Se ajusta a una recta el tramo de Ia señal en el que Ia herramienta se aproxima al material. Será una recta prácticamente horizontal. " Se aproxima a otra recta el tramo de Ia señal en el que aumenta el torque hasta que se estabiliza en Ia zona de corte. • The section of the signal in which the tool approaches the material is adjusted to a straight line. It will be a practically horizontal line. "The section of the signal in which the torque increases until it stabilizes in the cutting zone approaches another line.
" El punto en el que intersecan se puede considerar el punto en el que Ia herramienta toca Ia superficie. Se toma este punto como cero. " A partir de Ia velocidad de avance se estima el "Punto de salida", convirtiendo el tiempo en profundidad a Io largo del agujero (no es necesario cambiar el signo al cambiar el sentido del recorrido de Ia herramienta) . Coincide normalmente con el punto en el que el valor del torque decrece. Una vez delimitada Ia "Zona de corte" y el "Punto de salida" se definen varias zonas dentro de Ia "Zona de corte" (Figuras 4a y 4b): "The point at which they intersect can be considered the point at which the tool touches the surface. This point is taken as zero." From the speed of advance the "Exit point" is estimated, converting the time into depth along the length of the hole (it is not necessary to change the sign when changing the direction of travel of the tool). Normally coincides with the point where the torque value decreases. Once the "Cutting zone" and the "Exit point" have been defined, several zones are defined within the "Cutting zone" (Figures 4 a and 4b):
• se establece Ia "zona de salida" como Ia zona inmediatamente posterior al "punto de salida", que comprende desde que Ia punta de Ia broca toca Ia superficie de salida del agujero hasta que comienza a retroceder; • the "exit zone" is established as the zone immediately after the "exit point", which comprises from when the tip of the drill bit touches the exit surface of the hole until it begins to recede;
• se establece una "zona post-salida" que incluye sucesivamente Ia "zona de salida" y el retroceso de Ia broca hasta quedar fuera del agujero; • se establece una "zona pre-salida" inmediatamente anterior al "punto de salida". • a "post-exit zone" is established that successively includes the "exit zone" and the return of the bit until it is outside the hole; • a "pre-departure zone" is established immediately before the "departure point".
Además se define el "Nivel de referencia" (RL) como el valor medio alcanzado por Ia señal en Ia zona en Ia que Ia broca atraviesa el tramo interno del agujero en el cual es aproximadamente constante para unas condiciones fijas del proceso. En Ia Figura 4a se muestra un ejemplo en el que se ha utilizado una sola velocidad de avance a Io largo de todo el agujero, mientras que en Ia Figura 4b se han utilizado dos velocidades de avance diferentes. En el primer caso el nivel de referencia se calcula como el promedio del valor de Ia señal en Ia parte central del agujero, mientras que en el segundo caso se calcula como el promedio en el tramo correspondiente a Ia segunda velocidad. Se calcularía de forma similar si se utilizaran 3 velocidades a Io largo del agujero, sólo que calculado en el tramo correspondiente a Ia última velocidad. En el caso 4b sólo se ha variado Ia velocidad de avance, pero se obtendría un comportamiento similar cambiando Ia velocidad de corte o ambas (aunque no son casos frecuentes). De acuerdo con estas definiciones, y de acuerdo con el invento, se definen a su vez cinco magnitudes que son sensibles a Ia formación de rebaba (Figura 5): Furthermore, the "Reference level" (RL) is defined as the average value reached by the signal in the area in which the drill bit passes through the internal section of the hole in which it is approximately constant for fixed process conditions. Figure 4a shows an example in which a single forward speed has been used throughout the entire hole, while in Figure 4b two different forward speeds have been used. In the first case the reference level is calculated as the average of the value of the signal in the central part of the hole, while in the second case it is calculated as the average in the section corresponding to the second speed. It would be calculated in a similar way if 3 speeds were used along the length of the hole, only calculated in the section corresponding to the last speed. In case 4b, only the forward speed has been varied, but a similar behavior would be obtained by changing the cutting speed or both (although these are not frequent cases). According to these definitions, and according to the invention, five quantities are defined in turn that are sensitive to the formation of burr (Figure 5):
• Mínimo relativo (N) después de Ia salida de Ia herramienta. Se mide el mínimo en Ia "Zona de salida" (Minimun) y se divide por el nivel de referencia (Reference Level). • Relative minimum (N) after leaving the tool. The minimum is measured in the "Output Zone" (Minimun) and is divided by the reference level (Reference Level).
N = Minimun/Reference Level N = Minimun / Reference Level
Si este mínimo es demasiado alto indica que Ia rebaba está fuera de los requerimientos. Esta magnitud es Ia que mejor detecta las señales asociadas a rebabas muy grandes. If this minimum is too high, it indicates that the burr is outside the requirements. This magnitude is the one that best detects the signals associated with very large burrs.
• Anchura (Width, W) de las perturbaciones en Ia "Zona post-salida". Si es demasiado grande indica rebaba fuera de requerimientos. • Altura (Height, H) de las perturbaciones en Ia "Zona postsalida". Si es demasiado grande indica rebaba fuera de requerimientos. • Width (Width, W) of the disturbances in the "Post-exit zone". If it is too large it indicates a burr out of requirements. • Height (Height, H) of the disturbances in the "Post-output zone". If it is too large it indicates a burr out of requirements.
• Pendiente (Slope, S) de Ia curva durante Ia salida de Ia herramienta. Si es pequeña rebaba fuera de requerimientos. • Slope (S) of the curve during the tool exit. If it is small burr out of requirements.
Las 3 últimas (W, H, S) son las más interesantes para rebabas intermedias, cercanas a los umbrales permitidos en el sector aeronáutico. The last 3 (W, H, S) are the most interesting for intermediate burrs, close to the thresholds allowed in the aeronautical sector.
• Máximo relativo (M) antes de Ia salida de Ia herramienta. Para calcularlo se mide el máximo de Ia señal en un cierto rango antes de Ia salida de Ia herramienta (Maximun) y se divide por el promedio de Ia señal durante el tiempo de corte (Reference Level): • Relative maximum (M) before the exit of the tool. To calculate it, the maximum of the signal in a certain range is measured before of the tool output (Maximun) and is divided by the average of the signal during the cut-off time (Reference Level):
M = Maximun/Reference Level M = Maximun / Reference Level
Si este máximo es demasiado alto indica que Ia rebaba está fuera de los requerimientos. If this maximum is too high, it indicates that the burr is outside the requirements.
Esta es Ia magnitud menos interesante, ya que se incumple en una proporción muy baja de casos, aunque para procesos muy rigurosos es también útil. This is the least interesting magnitude, since it is breached in a very low proportion of cases, although for very rigorous processes it is also useful.
Las características H y W están más allá de Ia propia operación de taladrado, ya que el intervalo en el que se calculan incluye el retroceso del cabezal. Una vez hecho el agujero, Ia broca sale una cierta distancia más allá de Ia superficie de salida y retrocede rápidamente. Idealmente ya no debería cortar durante este tramo de Ia señal y por tanto el par debería adquirir valores próximos a cero. Sin embargo, en muchas ocasiones aparecen perturbaciones, que indican una formación no deseada de rebaba. De ahí que también sea necesario tener en cuenta estas magnitudes. c) Calibración del sistema de monitorización The characteristics H and W are beyond the drilling operation itself, since the interval in which they are calculated includes the recoil of the head. Once the hole is made, the drill bit comes out a certain distance beyond the outlet surface and quickly reverses. Ideally, it should no longer cut during this section of the signal and therefore the pair should acquire values close to zero. However, on many occasions disturbances appear, indicating an undesired burr formation. Hence, it is also necessary to take into account these magnitudes. c) Calibration of the monitoring system
Una vez desarrollado un algoritmo para calcular automáticamente los atributos sensibles a Ia formación de rebaba se procede a calibrar el sistema de monitorización: Once an algorithm has been developed to automatically calculate the attributes sensitive to burr formation, the monitoring system is calibrated:
• Se establece un proceso fijado de taladrado en el que se fija el valor de las variables del proceso en las condiciones de producción que interesen al usuario (máquina, herramienta, parámetros del proceso, etc). • A fixed drilling process is established in which the value of the process variables is set under the conditions of production that interest the user (machine, tool, process parameters, etc.).
• Se establece Ia máxima altura de rebaba admitida a partir de los requerimientos del usuario. • Se establece un plan de ensayos en las condiciones del proceso fijado. • The maximum permitted burr height is established based on user requirements. • A test plan is established under the conditions of the established process.
• Se realizan los ensayos y en cada uno de ellos se capta Ia señal procedente del regulador asociado al motor del cabezal. • The tests are carried out and the signal from the regulator associated with the spindle motor is captured in each of them.
• Se miden mediante un método directo estándar (rugosímetro, microscopio, etc.) las alturas máximas alcanzadas por Ia rebaba a Ia salida de cada agujero. Se obtendrán diferentes niveles de rebaba. • The maximum heights reached by the burr at the exit of each hole are measured by a standard direct method (roughness meter, microscope, etc.). Different levels of burr will be obtained.
• Se implementa un algoritmo para calcular los atributos descritos (N, W, H, S, M) a partir de las señales capturadas en los ensayos de calibración. • An algorithm is implemented to calculate the attributes described (N, W, H, S, M) from the signals captured in the calibration tests.
• Dependiendo del valor de altura máxima admitida se deberán uno o varios de estos atributos: • Depending on the value of the maximum height allowed, one or more of these attributes will be due:
" Si los requerimientos en altura máxima de rebaba no son excesivamente rigurosos el parámetro fundamental es el valor del mínimo relativo (N). "If the maximum burr height requirements are not excessively rigorous, the fundamental parameter is the value of the relative minimum (N).
" Si los requerimientos en altura máxima de rebaba son muy rigurosos se deberá utilizar el valor de anchura y altura de las perturbaciones y Ia pendiente (W, H y S). Además se puede incluir el valor del máximo relativo (M), aunque el porcentaje de agujeros que incumplen esta condición es muy bajo. "If the maximum burr height requirements are very rigorous, the value of width and height of the disturbances and the slope (W, H and S) should be used. In addition, the value of the relative maximum (M), although the percentage of holes that do not meet this condition is very low.
• Por comparación con las medidas directas de rebaba en cada agujero se determina los atributos que se van a utilizar. • Se diseña un método para monitorizar rebabas por encima de los requerimientos: • By comparison with the direct burr measurements in each hole, the attributes to be used are determined. • A method is designed to monitor burrs above the requirements:
" Puede establecerse un valor de comparación para cada uno de los atributos elegidos por diferentes métodos estándar: mínimo que satisface los requerimientos, ajuste lineal por mínimos cuadrados, métodos de lógica borrosa, etc. La rebaba será aceptable si se cumple sucesivamente: N < Nc, M < Mc, W< Wc, H < Ho, S > Sc, (si no se eligen todos los atributos, se sigue el mismo orden para los elegidos). "A comparison value can be established for each of the attributes chosen by different standard methods: minimum that satisfies the requirements, linear adjustment for least squares, fuzzy logic methods, etc. The burr will be acceptable if it is successively fulfilled: N <Nc , M <Mc, W <Wc, H <Ho, S> Sc, (if all attributes are not chosen, the same order is followed for the chosen ones).
" Igualmente se puede diseñar y entrenar una red neuronal que utilice como entradas los atributos elegidos, entre otros (puede ser útil por ejemplo utilizar los parámetros de proceso como entradas con el fin de generalizar Ia validez de Ia red a diferentes condiciones de proceso) y como una salida de Ia red se tomará el nivel de rebaba, que puede adoptar varios niveles definidos por el interés del usuario. Una vez desarrollado el algoritmo se ¡mplementa en el control. Las señales se capturan continuamente durante el taladrado y en el caso de que alguno de los agujeros no cumpla con los requerimientos se avisará al operario o se guardará un histórico para adoptar las medidas apropiadas, por ejemplo, desbarbar únicamente esos agujeros con altura de rebaba por encima de los requerimientos establecidos. Ejemplo: "It is also possible to design and train a neural network that uses the chosen attributes as inputs, among others (it may be useful, for example, to use the process parameters as inputs in order to generalize the validity of the network to different process conditions) and The burr level will be taken as an output from the network, which can adopt various levels defined by the user's interest. Once the algorithm has been developed, it is implemented in the control. The signals are continuously captured during drilling and in the case of If any of the holes do not meet the requirements, the operator will be notified or a record will be kept to take the appropriate measures, for example, deburring only those holes with a burr height above the established requirements. Example:
• Hemos considerado una broca TF B105 de Kennametal de diámetro 10mm sobre placas de aluminio Al 7075-T6 de espesores 12 y 25mm. • No se ha utilizado lubricante (taladrado en seco). • We have considered a Kennametal TF B105 drill bit with a diameter of 10mm on Al 7075-T6 aluminum plates of 12 and 25mm thicknesses. • No lubricant (dry drilling) has been used.
• El rango de parámetros de proceso es el siguiente: " Velocidad de corte: 150-250 m/min. • The process parameter range is as follows: "Cutting speed: 150-250 m / min.
• Velocidad de avance: 0.2-0.5 mm/rev. • Feed rate: 0.2-0.5 mm / rev.
• Se ha utilizado un fondo de escala de un 200% para Ia señal de voltaje extraída de los reguladores. • A 200% full scale has been used for the voltage signal extracted from the regulators.
• Se ha fijado el límite de altura de rebaba aceptable en 1 27 mieras (Hb). • The acceptable burr height limit has been set at 1 27 microns (Hb).
• Se han capturado las señales con una frecuencia de muestreo de 5000 Hz. Se ha representado Ia señal en función de Ia profundidad del agujero, es decir, se ha convertido el tiempo en profundidad (mm), tomando como cero el punto donde Ia broca toca el material. • The signals with a sampling frequency of 5000 Hz have been captured. The signal has been represented as a function of the depth of the hole, that is, the time has been converted into depth (mm), taking the point where the drill bit is zero. touch the material.
• El rango utilizado para calcular el máximo y mínimo relativo (M y N) se ha establecido en + /- 4mm entorno al punto de salida de Ia broca, equivalente al espesor del material. Por tanto, este rango incluye unos milímetros antes de que Ia broca salga del material, Ia caída en el voltaje que coincide con Ia salida de Ia herramienta y un tramo después de Ia salida. En Ia Figura 4 este rango entorno al "Punto de salida" corresponde a Ia "Zona pre-salida" y Ia "Zona de salida". • La altura y anchura de las perturbaciones (H y W) se ha calculado en el rango que va del "Punto de salida" de Ia broca hasta que el cabezal decelera, incluyendo el retroceso del cabezal, es decir en Ia "Zona post-salida" de Ia Figura 4. « La pendiente se ha ajustado por mínimos cuadrados en Ia• The range used to calculate the relative maximum and minimum (M and N) has been established at +/- 4mm around the exit point of the bit, equivalent to the thickness of the material. Therefore, this range includes a few millimeters before the drill bit leaves the material, the drop in voltage that coincides with the output of the tool and a section after the output. In Figure 4 this range around the "Exit point" corresponds to the "Pre-exit zone" and the "Exit zone". • The height and width of the disturbances (H and W) have been calculated in the range that goes from the "Exit point" of the bit until the head decelerates, including the recoil of the head, that is to say in the "Post- output "of Figure 4.« The slope has been adjusted by least squares in the
"Zona de salida", más concretamente calculando el rango en el que el valor del torque disminuye monótonamente. "Output zone", more specifically calculating the range in which the torque value decreases monotonously.
• La transformación de voltios a unidades de Torque para Ia máquina utilizada es: Vτ {V) - TN{N . m) • The transformation from volts to Torque units for the machine used is: V τ {V) - T N {N. m)
donde TN = 16.97 (N m) es el torque nominal de Ia máquina equivalente a 5 (V) y VT es el voltaje medido del regulador del cabezal. • Los valores de comparación establecidos son: where TN = 16.97 (N m) is the nominal torque of the machine equivalent to 5 (V) and VT is the measured voltage of the head regulator. • The established comparison values are:
" Mc = nivel de referencia + 1 (V). "Mc = reference level + 1 (V).
Se ha implementado un algoritmo eliminatorio, de manera que han de satisfacerse sucesivamente: N < Nc, M < Mc, W<Wc, H < Hc, S>Sc. Si una condición no se satisface no es necesario calcular las siguientes- Con estos valores Ia capacidad de predicción del algoritmo de monitorización es de un 92%. A elimination algorithm has been implemented, so that they must be satisfied successively: N <Nc, M <Mc, W <Wc, H <Hc, S> Sc. If a condition is not satisfied, it is not necessary to calculate the following. With these values, the prediction capacity of the monitoring algorithm is 92%.
En Ia Figura 6 se muestran varios ejemplos de señales con distinto nivel de rebaba. a) Velocidad de corte = 150 m/min, avance = 0.2 mm/rev. b) Velocidad de corte = 150 m/min, avance = 0.3 mm/rev. c) Velocidad de corte = 150 m/min, avance = 0.2 mm/rev. d) Velocidad de corte = 1 50 m/min, avance = 0.3 mm/rev. Los resultados obtenidos son los siguientes para cada uno de los atributos: Figure 6 shows several examples of signals with different burr levels. a) Cutting speed = 150 m / min, feed = 0.2 mm / rev. b) Cutting speed = 150 m / min, feed = 0.3 mm / rev. c) Cutting speed = 150 m / min, feed = 0.2 mm / rev. d) Cutting speed = 1 50 m / min, feed = 0.3 mm / rev. The results obtained are as follows for each of the attributes:
Signal M N H W S HB (μm) OutputSignal M N H W S HB (μm) Output
(a) 0.12 0.39 - - - 315 Bad(a) 0.12 0.39 - - - 315 Bad
(b) 0.57 0,08 1.44 10.9 56° 148 Bad(b) 0.57 0.08 1.44 10.9 56 ° 148 Bad
(c) 0.31 0.03 0.52 0 35° 183 Bad(c) 0.31 0.03 0.52 0 35 ° 183 Bad
(d) 0.46 0.05 0.78 0 57° 80 OK (d) 0.46 0.05 0.78 0 57 ° 80 OK
donde HB es Ia rebaba medida en el agujero y Output es Ia salida del algoritmo de monitorización. where HB is the burr measured in the hole and Output is the output of the monitoring algorithm.
Normalmente los peores niveles de rebaba se manifiestan en una señal muy irregular, donde el mínimo a Ia salida M es muy alto (ejemplo de Ia Figura 6a). En ese caso ya no es necesario calcular los demás atributos. Conclusiones Normally the worst levels of burr are manifested in a very irregular signal, where the minimum at output M is very high (example in Figure 6a). In that case it is no longer necessary to calculate the other attributes. Conclusions
En este invento se ha desarrollado el primer método de monitorización de rebabas durante el taladrado. El algoritmo está basado en el análisis de las señales procedentes del regulador del motor del cabezal. Esto facilita y abarata Ia implementación del método en el control para utilizarlo de forma automática. La fiabilidad de este método está por encima del 92% para un rango de parámetros extenso en condiciones de alta velocidad de taladrado en seco para aleaciones de aluminio, por ejemplo, Al 7075-T6. In this invention the first method of monitoring burrs during drilling has been developed. The algorithm is based on the analysis of the signals coming from the spindle motor regulator. This facilitates and lowers the implementation of the method in the control to use it automatically. The reliability of this method is above 92% for an extensive parameter range under high speed dry drilling conditions for aluminum alloys, for example, Al 7075-T6.
Claims
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/ES2005/000665 WO2007065959A1 (en) | 2005-12-07 | 2005-12-07 | Method for monitoring burr formation in processes involving the drilling of parts |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/ES2005/000665 WO2007065959A1 (en) | 2005-12-07 | 2005-12-07 | Method for monitoring burr formation in processes involving the drilling of parts |
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| Publication Number | Publication Date |
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| WO2007065959A1 true WO2007065959A1 (en) | 2007-06-14 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/ES2005/000665 Ceased WO2007065959A1 (en) | 2005-12-07 | 2005-12-07 | Method for monitoring burr formation in processes involving the drilling of parts |
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| Country | Link |
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| WO (1) | WO2007065959A1 (en) |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH04110708A (en) * | 1990-08-31 | 1992-04-13 | Suzuki Motor Corp | Device for measuring surface |
| JPH10296589A (en) * | 1997-04-25 | 1998-11-10 | Yamazaki Mazak Corp | Drill cutting loss prediction device and drill cutting loss prediction method |
| US20030187624A1 (en) * | 2002-03-27 | 2003-10-02 | Joze Balic | CNC control unit with learning ability for machining centers |
-
2005
- 2005-12-07 WO PCT/ES2005/000665 patent/WO2007065959A1/en not_active Ceased
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH04110708A (en) * | 1990-08-31 | 1992-04-13 | Suzuki Motor Corp | Device for measuring surface |
| JPH10296589A (en) * | 1997-04-25 | 1998-11-10 | Yamazaki Mazak Corp | Drill cutting loss prediction device and drill cutting loss prediction method |
| US20030187624A1 (en) * | 2002-03-27 | 2003-10-02 | Joze Balic | CNC control unit with learning ability for machining centers |
Non-Patent Citations (2)
| Title |
|---|
| PATENT ABSTRACTS OF JAPAN 26 February 1999 (1999-02-26) * |
| PATENT ABSTRACTS OF JAPAN vol. 016, no. 357 31 July 1992 (1992-07-31) * |
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