Digital Library

Advanced millling simulation and information management

• Kai Mecke
• Tobias Surmann

(2023). ECMS 2023, 37th Proceedings
Edited by: Enrico Vicario, Romeo Bandinelli, Virginia Fani, Michele Mastroianni, European Council for Modelling and Simulation.
DOI: http://doi.org/10.7148/2023
ISSN: 2522-2422 (ONLINE)
ISSN: 2522-2414 (PRINT)
ISSN: 2522-2430 (CD-ROM)
ISBN: 978-3-937436-80-7
ISBN: 978-3-937436-79-1 (CD) Communications of the ECMS Volume 37, Issue 1, June 2023, Florence, Italy June 20th – June 23rd, 2023

https://doi.org/10.7148/2023-0387

Kai mecke, Tobias surmann (2023). Advanced Millling Simulation and Information Management, ECMS 2023, Proceedings Edited by: Enrico Vicario, Romeo Bandinelli, Virginia Fani, Michele Mastroianni, European Council for Modelling and Simulation. doi:10.7148/2023-0387

This paper presents results of coupling actual milling processes from the aircraft industry to a related simulation by collecting process data.
This allows both, an immediate real time process monitoring on the one hand and a long-term evaluation of the process reliability on the other hand. The immediate process monitoring compares the time series of the spindle torque with the precomputed simulation results and stops the milling process when there is a significant deviation between both. The long-term evaluation of the spindle torque is used to find anomalies in the milling processes like a drift of cutting forces, frequent tool breakage in the same NC-program over a lot of workpieces, or to analyse the tool wear behaviour.
To build up such a system the data flow between the NC-programming, the machines, and the simulation system had to be analysed to build an information model. This has been necessary for an optimal development of the communication channels between all subsystems (CAM-system, milling machine, process monitoring system, and simulation) which were originally not meant to work together. Therefore, a big challenge has been to get from a theoretical information model to a running short- and long-term process monitoring system that not only works in a university environment but in the actual aircraft industry as well.