KR102630086B1 - Apparatus and method for predicting the life of cutting tool and active control of cutting condition - Google Patents

Abstract

A method for predicting the life of a cutting tool and actively controlling cutting conditions is disclosed, and the method for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present application includes (a) the total power consumption by cutting processing, the cutting processing Obtaining processing condition information and processing time information of the cutting tool being performed, (b) calculating the wear level and remaining life of the cutting tool based on the total power consumption, the processing condition information, and the processing time information. and (c) adaptively controlling processing conditions of the cutting tool based on the calculated wear level and remaining life.

Description

Apparatus and method for predicting the life of a cutting tool and actively controlling cutting conditions {APPARATUS AND METHOD FOR PREDICTING THE LIFE OF CUTTING TOOL AND ACTIVE CONTROL OF CUTTING CONDITION}

The present application relates to an apparatus and method for predicting the life of a cutting tool and actively controlling cutting conditions.

Machine tools are used to process various metal or non-metal materials into predetermined shapes and dimensions or to perform more precise processing on semi-materials. Among these machine tools, machines that perform cutting processing include lathes. , milling machines, machining centers, drilling machines, boring machines, grinding machines, gear processing machines, special processing machines, etc.

Wear of tools is caused by various causes such as physical and chemical actions, and in actual machining, they act in complex ways, so it is not easy to predict and determine the tendency of wear. In particular, tool wear inevitably occurs as cutting processing is performed, and its causes are diverse, including wear between the cutting tool and the processing material, chemical reactions, and high temperatures generated during processing. Additionally, because these causes act in complex ways during machining, it is difficult to accurately predict the development of tool wear.

On the other hand, flank wear occurs due to friction between the clearance surface of the tool and the machined surface. Tool wear can be judged based on the flank wear width (VB). As cutting progresses, the flank wear width increases and as cutting resistance increases, power consumption tends to increase.

In this regard, various studies are being conducted on predicting the lifespan of cutting tools, but these conventional studies have limitations in that they measure cutting power consumption using cutting load commands, resulting in slow calculation speed and poor prediction accuracy.

The technology behind this application is disclosed in Korean Patent Publication No. 10-1496578.

The purpose of this application is to solve the problems of the prior art described above. By utilizing power consumption data from cutting processing, the wear level and remaining life of the cutting tool are predicted, and the cutting tool can be adaptively controlled based on this. The purpose is to provide a device and method for predicting tool life and actively controlling cutting conditions.

However, the technical challenges sought to be achieved by the embodiments of the present application are not limited to the technical challenges described above, and other technical challenges may exist.

As a technical means for achieving the above-described technical problem, the method for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present application includes (a) the total power consumption by cutting processing, the cutting capacity for performing the cutting processing; Obtaining processing condition information and processing time information of the tool, (b) calculating the wear level and remaining life of the cutting tool based on the total power consumption, the processing condition information, and the processing time information, and (c) ) It may include adaptively controlling the processing conditions of the cutting tool based on the calculated wear level and remaining life.

Additionally, in step (c), the processing conditions may be changed to increase the remaining life or the processing conditions may be changed to shorten the processing time using the cutting tool.

Additionally, the processing conditions may include rotational speed and feed speed of the cutting tool.

Additionally, step (c) may include (c1) increasing the transfer speed so that the processing time is shortened.

Additionally, step (c) may include (c2) lowering at least one of the rotation speed and the transfer speed to increase the remaining lifespan.

In addition, the method for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present application is (d) when the remaining life is less than a preset threshold or the wear level exceeds the preset wear level, the cutting tool It may include generating an exchange request.

In addition, step (b) includes (b1) calculating a cutting length based on the processing condition information and the processing time information, and (b2) machine power calculated according to the processing condition information for the total power consumption. Calculating cutting power consumption by subtracting the consumption, (b3) calculating a material removal rate corresponding to the cutting power consumption, (b4) cutting according to the cutting power consumption and the processing condition information stored in a previously established database. calculating the wear rate of the cutting tool based on the wear level of the tool; and (b5) calculating an expected time required for the wear level to reach a preset critical level based on the wear rate, and calculating the expected time and It may include calculating the remaining life based on the processing time information.

Additionally, step (b) may be re-performed by reflecting the changed processing condition information when a change in the processing condition information is detected.

In addition, when a change in at least one of the rotation speed and the feed speed is detected, step (b) recalculates the expected time by reflecting the changed processing condition information, and changes the expected time in the recalculated time. The remaining lifespan can be updated by subtracting the processing time information prior to detection.

In addition, when a change in at least one of the cutting width and cutting depth among the processing condition information is detected, step (b) recalculates the material removal rate by reflecting the changed processing condition information, and recalculates the recalculated material. It may include a step of recalculating cutting power consumption according to the removal rate.

Additionally, a change in at least one of the cutting width and cutting depth may be detected based on the difference between a previously calculated material removal rate corresponding to the cutting power consumption and a material removal rate recalculated according to the change in the cutting power consumption.

Additionally, a change in at least one of the cutting width and cutting depth may be detected when the cutting process corresponding to complex shape processing is performed.

Meanwhile, the cutting tool life prediction and cutting condition active control device according to an embodiment of the present application collects the total power consumption by cutting processing, processing condition information of the cutting tool performing the cutting processing, and processing time information. A unit, a calculation unit that calculates the wear level and remaining life of the cutting tool based on the total power consumption, the processing condition information, and the processing time information, and the processing condition of the cutting tool based on the calculated wear level and remaining life. It may include an active control unit that adaptively controls.

Additionally, the active control unit may change the processing conditions to increase the remaining life or change the processing conditions to shorten the processing time using the cutting tool.

Additionally, the active control unit may increase the feed rate to shorten the processing time or lower at least one of the rotation speed and the feed rate to increase the remaining lifespan.

In addition, the device for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present application requests replacement of the cutting tool when the remaining life is less than a preset threshold or the wear level exceeds a preset wear level. It may include a notification generator that generates a notification.

In addition, the calculation unit calculates the cutting length based on the processing condition information and the processing time information, and calculates the cutting power consumption by subtracting the machine power consumption calculated according to the processing condition information from the total power consumption, Calculating a material removal rate corresponding to the cutting power consumption, calculating the wear rate of the cutting tool based on the processing condition information stored in a pre-built database and the wear level of the cutting tool according to the cutting power consumption, Based on the wear rate, the expected time required for the wear level to reach a preset critical level can be calculated, and the remaining lifespan can be calculated based on the expected time and the processing time information.

The above-described means of solving the problem are merely illustrative and should not be construed as intended to limit the present application. In addition to the exemplary embodiments described above, additional embodiments may be present in the drawings and detailed description of the invention.

According to the above-mentioned means of solving the problem of this application, the wear level and remaining life of the cutting tool are predicted by utilizing the power consumption data by cutting processing, and based on this, the life of the cutting tool can be predicted to adaptively control the cutting tool. and a device and method for actively controlling cutting conditions.

According to the above-described means of solving the problem of the present application, the lifespan of a cutting tool can be accurately predicted by directly calculating the cutting power consumption based on the total power consumption and machine power consumption generated during machining.

According to the above-mentioned means of solving the problem of this application, it is possible to calculate the change in expected life that fluctuates due to changes in cutting conditions during processing, and to confirm changes in cutting width and cutting depth that cannot be directly measured when machining relatively complex shapes. Thus, the lifespan of cutting tools can be accurately predicted through power consumption and material removal rate.

According to the above-described means of solving the problem of the present application, the life of the cutting tool for that condition can be predicted through calculation of the initial wear rate for the cutting condition input by the user, so that it is possible to quickly configure the life data of the cutting tool for various cutting conditions.

According to the above-mentioned means of solving the problem of the present invention, cutting tool life and wear rate data of various cutting conditions are compared and calculated from various angles through cutting condition adaptive control to meet the needs of the user or cutting tool, such as reducing machining time and cutting tool wear. Cutting conditions that match the machining environment can be presented.

However, the effects that can be obtained herein are not limited to the effects described above, and other effects may exist.

1 is a schematic diagram of a device for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present disclosure.
Figure 2 is a conceptual diagram for explaining the detailed functions and operation flow of the device for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present application.
Figure 3a is a diagram for explaining cutting power consumption. For reference, in Figure 3a, the horizontal axis represents processing time (Time), the vertical axis represents power consumption, P _total represents total power consumption, P _machine represents machine power consumption, and P _cutting represents cutting power consumption.
3B and 3C are graphs showing the correlation between cutting power consumption and material removal rate. For reference, in FIG. 3B, the horizontal axis is the material removal rate (MRR) and the vertical axis is power consumption, and in FIG. 3C, the horizontal axis is the material removal rate (MRR) and the vertical axis is cutting power consumption.
FIGS. 4A and 4B are diagrams for explaining the correlation between parameters such as cutting power consumption and material removal rate and the wear level and remaining life of the cutting tool. For reference, in FIGS. 4A and 4B, the horizontal axis is tool life, and the vertical axis is cutting power consumption, but the point marked with an (End of tool life at condition 1), and the point marked with an In addition, the point marked with an X on the relatively left side of the graph in Figure 4b represents the current status, and the point marked with an The horizontal axis length from (Current status) means the measured value of machining time, and the horizontal axis length from the current status (Current status) to the end of tool life (End of tool life) means the remaining tool life. Remaining tool life (Remaining tool life).
Figures 5a and 5b are diagrams illustrating changes in wear level and remaining lifespan according to changes in processing conditions. For reference, in Figure 5a, the horizontal axis is machining time (Time), the vertical axis is cutting power consumption, and the point marked with an condition 1), and the point marked with an 1 to 2), and the length of the horizontal axis from the origin to the point of change in cutting conditions means the measured value of the machining time, and the tool life of cutting condition 2 from the point of change in cutting conditions (End) The horizontal axis length up to of tool life at condition 2) represents the remaining tool life after condition change. In addition, in (a) of Figure 5b, the horizontal axis is the material removal rate (MRR), the vertical axis is cutting power consumption, and in (b) of Figure 5b, the horizontal axis is processing time (Time), and the vertical axis is cutting power. Cutting power consumption, where MRR ₀ and P _cutting,0 are the values derived before the cutting conditions are changed ('Before'), and MRR _i and P _cutting,i are the values derived after the cutting conditions are changed ('After'). The derived values are shown respectively.
Figure 6 is an operation flowchart for a method for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present application.
Figure 7 is a detailed operational flowchart for the process of calculating the wear level and remaining life of a cutting tool.
Figure 8 is a detailed operation flowchart of a process for adaptively controlling the machining conditions of a cutting tool.

Below, with reference to the attached drawings, embodiments of the present application will be described in detail so that those skilled in the art can easily implement them. However, the present application may be implemented in various different forms and is not limited to the embodiments described herein. In order to clearly explain the present application in the drawings, parts that are not related to the description are omitted, and similar reference numerals are assigned to similar parts throughout the specification.

Throughout this specification, when a part is said to be “connected” to another part, this means not only “directly connected” but also “electrically connected” or “indirectly connected” with another element in between. "Includes cases where it is.

Throughout this specification, when a member is said to be located “on”, “above”, “at the top”, “below”, “at the bottom”, or “at the bottom” of another member, this means that a member is located on another member. This includes not only cases where they are in contact, but also cases where another member exists between two members.

Throughout the specification of the present application, when a part "includes" a certain component, this means that it may further include other components rather than excluding other components unless specifically stated to the contrary.

The present application relates to an apparatus and method for predicting the life of a cutting tool and actively controlling cutting conditions.

1 is a schematic diagram of a device for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present disclosure.

Referring to Figure 1, the cutting tool life prediction and cutting condition active control device 100 (hereinafter referred to as the 'control device 100') according to an embodiment of the present application includes a collection unit 110, a calculation unit ( 120), an active control unit 130, and a notification generating unit 140.

Meanwhile, the collection unit 110, calculation unit 120, active control unit 130, and notification generation unit 140 of the control device 100 are connected to each other or between the control device 100 and the user terminal (not shown) through a network. Can communicate. The network 20 refers to a connection structure that allows information exchange between nodes such as terminals and servers. Examples of such networks include the 3rd Generation Partnership Project (3GPP) network and Long Term Evolution (LTE). Network, 5G network, WIMAX (World Interoperability for Microwave Access) network, Internet, LAN (Local Area Network), Wireless LAN (Wireless Local Area Network), WAN (Wide Area Network), PAN (Personal Area Network), It includes, but is not limited to, a wifi network, Bluetooth network, satellite broadcasting network, analog broadcasting network, and DMB (Digital Multimedia Broadcasting) network.

User terminals (not shown) include, for example, smartphones, smart pads, tablet PCs, PCS (Personal Communication System), GSM (Global System for Mobile communication), PDC (Personal Digital Cellular), and PHS. (Personal Handyphone System), PDA (Personal Digital Assistant), IMT (International Mobile Telecommunication)-2000, CDMA (Code Division Multiple Access)-2000, W-CDMA (W-Code Division Multiple Access), Wibro (Wireless Broadband Internet) It can be any type of wireless communication device, such as a terminal. For example, in the description of the embodiment of the present application, a user terminal (not shown) may be a device owned by a user who operates the cutting tool, such as a worker, a manager, or an inspector who manages the cutting tool.

Hereinafter, specific functions and operations of the control device 100 will be described with reference to FIGS. 2 to 5B.

Figure 2 is a conceptual diagram for explaining the detailed functions and operation flow of the device for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present application.

Referring to FIG. 2, the control device 100 is linked to a database 101 that stores various information about the cutting tool (tool information), various relational expressions for calculating the wear level and remaining life of the cutting tool, and a calculation model. It can be. By way of example, the database 101 may be a sub-configuration mounted on the control device 100. As another example, the control device 100 may be linked with a database 101 built independently from the control device 100 to obtain (receive) and utilize various data stored internally from the database 101.

Specifically, the database 101 contains tool information (tool diameter D), a machine power consumption (P _machine ) model for cutting conditions (rotational speed N , feed speed Feed ), and cutting power consumption (P _cutting ) under specific cutting conditions. Data including the wear state of the cutting tool, the material removal rate ( MRR ) relationship for cutting power consumption (P _cutting ), and the wear rate for cutting conditions can be stored. Meanwhile, among the data stored in the database 101, data related to wear speed for cutting conditions may be items that are continuously updated according to the calculation results of the calculation unit 120, which will be described later.

Referring to FIGS. 1 and 2 , the collection unit 110 may obtain the total power consumption (P _total ) due to cutting processing, processing condition information of a cutting tool performing cutting processing, and processing time information.

In this regard, the processing conditions of the cutting tool may include the rotational speed ( N ) and the feed speed ( Feed ) of the cutting tool. Additionally, according to an embodiment of the present application, the processing condition information obtained by the collection unit 110 may be initially set to a value input by the user through a user terminal (not shown).

In addition, the machining time (T _machining ) of the cutting tool is measured from the time the cutting tool starts the process of removing the workpiece (work material), and may mean data measuring the actual machining time of the cutting tool.

The calculation unit 120 may calculate the wear level and remaining life of the cutting tool based on the obtained total power consumption (P _total ), machining condition information, and machining time information (T _machining ).

Specifically, the calculation unit 120 first calculates the cutting length (L) based on machining condition information and machining time information (T _machining ), including cutting speed-related parameters such as feed speed ( Feed ) and rotation speed ( N ) of the cutting tool. ) can be calculated.

In addition, _the calculation unit 120 may calculate the cutting power consumption (P cutting) by subtracting the machine power consumption (P _machine ) calculated according to processing condition information from the measured total power consumption (P _total ).

Figure 3a is a diagram for explaining cutting power consumption.

Referring to FIG. 3A, the total power consumption (P _total ) obtained by the collection unit 110 may satisfy the machine power consumption (P _machine ) and cutting power consumption (P _cutting ) and Equation 1 below.

[Equation 1]

In this regard, the calculation unit 120 obtains machine power by substituting (inputting) the cutting conditions (in other words, machining condition information, etc.) of the cutting tool currently performing machining into the machine power consumption model previously stored in the database 101. By removing the consumption (P _machine ) from the total power consumption (P _total ) obtained through the preceding data measurement process, the cutting power consumption (P _cutting ), which is the pure amount of power consumed in the cutting process, can be calculated.

According to an embodiment of the present application, the machine power consumption model stored in the database 101 can be given as Equation 2 below.

[Equation 2]

Here, f is a function that represents the machine power consumption model, N is the rotational speed of the cutting tool, and Feed is a parameter that represents the feed speed of the cutting tool.

3B and 3C are graphs showing the correlation between cutting power consumption and material removal rate.

Referring to Figures 3b and 3c, the cutting power consumption (P _cutting ) shows a positive correlation with the material removal rate ( MRR ), and the relationship between the cutting power consumption (P _cutting ) and the material removal rate ( MRR ) is the feed rate ( It may be determined depending on the type of cutting tool and workpiece (work material), regardless of detailed cutting conditions such as feed ) and rotation speed ( N ).

In relation to this, the calculation unit 120 may calculate the material removal rate ( MRR ) corresponding to the derived cutting power consumption (P _cutting ). In this regard, the calculation unit 120 specifically obtains the relationship between cutting power consumption (in other words, cutting power consumption) and material removal rate ( MRR ) from the database 101, and is currently based on the previously calculated cutting power consumption. You can calculate the material removal rate ( MRR ) value according to the cutting process.

In addition, according to an embodiment of the present application, the calculation unit 120 determines the specific cutting conditions of the cutting tool (i.e., rotational speed ( N ), feed speed ( Feed ), cutting length ( L ), material removal rate ( MRR ), etc. A computational model for cutting power consumption (P _cutting ) as a parameter can be derived.

In this regard, the calculation model for cutting power consumption (P _cutting ) can be defined as Equation 3 below.

[Equation 3]

Here, f is a function that refers to the calculation model for cutting power consumption (P _cutting ), N is the rotational speed of the cutting tool, Feed is the feed speed of the cutting tool, L is the calculated cutting length, and MRR is the material This parameter represents the removal rate.

In addition, the calculation unit 120 may calculate the wear rate of the cutting tool based on the wear level of the cutting tool according to the processing condition information and cutting power consumption (P _cutting ) stored in the previously established database 101.

FIGS. 4A and 4B are diagrams for explaining the correlation between parameters such as cutting power consumption and material removal rate and the wear level and remaining life of the cutting tool.

Referring to FIGS. 4A and 4B, based on the wear rate of the cutting tool derived by the calculation unit 120, the slope of the graph with the life of the cutting tool on the horizontal axis and the cutting power consumption (P _cutting ) on the vertical axis is It may be decided.

Meanwhile, referring to FIGS. 3C and 4A together, the relationship between cutting power consumption (P _cutting ) and material removal rate ( MRR ) shown in FIG. 3C is slightly affected by changes in rotation speed and feed speed of the cutting tool. On the other hand, since the lifespan of a cutting tool can be greatly affected by changes in detailed cutting conditions, as will be described in detail below, when a change in cutting conditions is detected, a recalculation process for the expected lifespan may be required.

Additionally, the calculation unit 120 may calculate the expected time required for the wear level to reach a preset critical level based on the calculated wear rate. For example, a point marked with an 'X' on the graph of FIG. 4A may indicate a state in which the wear level has reached a preset critical level or a state in which the life of the cutting tool has reached the end.

Additionally, the calculation unit 120 may calculate the remaining lifespan of the cutting tool based on the calculated expected time and machining time information. Specifically, referring to FIG. 4B, the calculation unit 120 calculates the current acquired by the collection unit 110 at the expected time until the wear level reaches a preset critical level or the cutting tool reaches the end of its life. The remaining tool life can be derived by subtracting the machining time, which is a measure of the condition.

The active control unit 130 may adaptively control the processing conditions of the cutting tool based on the wear level and remaining life calculated by the calculation unit 120.

Specifically, the active control unit 130 may control processing conditions of different aspects such as changing the processing conditions to increase the remaining life or changing the processing conditions to shorten the processing time using a cutting tool.

More specifically, the control device 100 calculates the wear level of the cutting tool to the user (e.g., an operator operating the cutting tool, a manager managing the cutting tool, an inspector, etc.) through a user terminal (not shown). And by providing information on the remaining life, it is possible to assist the user in making decisions to adjust detailed parameters related to the cutting process performed by the cutting tool by considering the remaining life of the cutting tool.

For example, when the user determines that the life (remaining life) of the cutting tool is sufficient and applies a user input requesting a reduction in machining time, the active control unit 130 adjusts the feed rate to shorten the machining time. It can be increased within the range below the preset upper limit. As an example, the upper limit applied when increasing the feed speed may be a specific value determined in consideration of the stability of the tool, which is determined depending on the type of cutting tool, type of workpiece (workpiece), etc.

As another example, when the active control unit 130 determines that the life (remaining life) of the cutting tool is insufficient and applies a user input requesting control to extend the life of the cutting tool, the remaining life of the cutting tool Active control can be performed to lower at least one of the rotation speed ( N ) and the feed speed ( Feed ) to increase.

The notification generator 140 may generate an exchange request signal requesting replacement of the cutting tool when the remaining life is less than a preset threshold or the wear level exceeds the preset wear level. For example, the generated cutting tool exchange request signal may be transmitted and output to a user terminal (not shown).

In other words, the control device 100 disclosed herein determines that there is no change in cutting conditions during processing, and the remaining life of the cutting tool calculated by the calculation unit 120 is reached or the wear level of the cutting tool is determined by the user-specified level. When a preset wear level is reached, a signal can be generated to terminate machining and command replacement of the cutting tool. In contrast, if the control device 100 determines that the calculated remaining life or wear level of the cutting tool is sufficient to continue performing the cutting process, the control device 100 may generate a command to allow the cutting tool to continue performing machining.

Hereinafter, the process of updating the wear level and expected remaining life according to changes in processing conditions will be described with reference to FIGS. 5A and 5B.

Figures 5a and 5b are diagrams illustrating changes in wear level and remaining lifespan according to changes in processing conditions.

Referring to FIGS. 5A and 5B , when a change in machining condition information is detected, the calculation unit 120 may re-perform the process of calculating the wear level and remaining life of the cutting tool by reflecting the changed machining condition information.

In this regard, according to an embodiment of the present application, when a change in at least one of the rotation speed ( N ) and the feed speed ( Feed ) is detected during machining using a cutting tool, the calculation unit 120 reflects the changed processing condition information and The remaining life can be updated by recalculating the expected time and subtracting the processing time information up to before the change in processing conditions was detected from the recalculated expected time.

Specifically, referring to FIG. 5A, the calculation unit 120 changes the processing condition associated with at least one of the rotation speed ( N ) and the feed speed ( Feed ) from the first condition (condition 1) to the second condition (condition 2). If something is detected at a specific point in time (e.g., the point indicated by the circle symbol in Figure 5a), the expected time associated with the wear level or life of the cutting tool is calculated again by reflecting the second condition (End of tool life at condition) 2) And, the updated remaining tool life (Remained tool life after condition change) can be derived by subtracting the measured machining time information (T _machining ) from the newly calculated expected time to the time when the change in machining conditions is detected.

In summary, the calculation unit 120 calculates the remaining life of the cutting tool and the current wear level based on the changed cutting conditions by removing the machining time measured through the data measurement step before the change from the overall life of the cutting tool under the changed cutting conditions. can do.

As another example, when a change in at least one of the cutting width (a _p ) and the cutting depth (a _e ) is detected during machining using a cutting tool, the calculation unit 120 determines the material removal rate ( MRR ) by reflecting the changed processing condition information. You can recalculate and recalculate the cutting power consumption (P _cutting ) according to the recalculated material removal rate ( MRR ). Additionally, the calculation unit 120 may update the remaining life of the cutting tool by reflecting the recalculated cutting power consumption (P _cutting ).

Meanwhile, according to an embodiment of the present application, a change in at least one of the cutting width (a _p ) and the cutting depth (a _e ) detected by the calculation unit 120 to recalculate the remaining life is the previously calculated cutting power consumption ( It may be detected based on the difference between the material removal rate ( MRR ) corresponding to P _cutting ) and the material removal rate ( MRR ) calculated again according to changes in cutting power consumption (P _cutting ).

For reference, processing conditions such as cutting width (a _p ), cutting depth (a _e ), etc. may change during processing if the cutting processing performed through a cutting tool corresponds to complex shape processing, and in this regard, disclosed herein. The control device 100 has the advantage of being able to precisely predict the wear level and remaining life of a cutting tool even for a cutting tool that performs complex shape processing.

In summary, the calculation unit 120 calculates the material removal rate ( MRR ₀ ) for the cutting power consumption (P _cutting,0 ) calculated in the previous data calculation step and the material removal rate ( MRR _i ) changed as the change in cutting power consumption is detected. Detects changes in cutting width and cutting depth by checking the difference, and responds based on the changed material removal rate ( MRR ) according to the relationship between cutting power consumption (P _cutting ) and material removal rate ( MRR ) stored in the database 101. By calculating the cutting power consumption (P _cutting,i ) and excluding the machining time measured before the change in machining conditions from the entire life of the cutting tool in the changed state, the remaining life and current wear level of the cutting tool can be recalculated. there is.

Below, we will briefly look at the operation flow of the present application based on the details described above.

Figure 6 is an operation flowchart for a method for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present application.

The method of predicting the life of a cutting tool and actively controlling cutting conditions shown in FIG. 6 can be performed by the control device 100 described above. Therefore, even if the content is omitted below, the content described about the control device 100 can be equally applied to the description of the method for predicting the life of a cutting tool and actively controlling cutting conditions.

Referring to FIG. 6, in step S11, the collection unit 110 collects (a) total power consumption by cutting processing (P _total ), processing condition information of the cutting tool performing cutting processing, and processing time information (T _machining ). It can be obtained.

Next, in step S12, the calculation unit 120 may calculate the wear level and remaining life of the cutting tool based on the total power consumption, processing condition information, and processing time information obtained in step S11 (b).

Next, in step S13, the active control unit 130 may (c) adaptively control the processing conditions of the cutting tool based on the wear level and remaining life calculated in step S12.

Specifically, in step S13, the active control unit 130 may change the processing conditions to increase the remaining life of the cutting tool or change the processing conditions to shorten the processing time using the cutting tool.

Next, in step S14, the notification generator 140 requests (d) replacement of the cutting tool when the remaining life calculated in step S12 is less than or equal to a preset threshold or the wear level calculated in step S12 exceeds the preset wear level. can be created.

In the above description, steps S11 to S14 may be further divided into additional steps or combined into fewer steps, depending on the implementation of the present disclosure. Additionally, some steps may be omitted or the order between steps may be changed as needed.

Figure 7 is a detailed operational flowchart for the process of calculating the wear level and remaining life of a cutting tool.

The process of calculating the wear level and remaining life of the cutting tool shown in FIG. 7 may be performed by the control device 100 described above. Therefore, even if the content is omitted below, the content described with respect to the control device 100 can be equally applied to the description of FIG. 7.

Referring to FIG. 7 , in step S121, the calculation unit 120 may calculate the cutting length ( L ) based on (b1) processing condition information and processing time information (T _machining ).

Next, in step S122, the calculation unit 120 may (b2) calculate the cutting power consumption (P _cutting ) by subtracting the machine power consumption calculated according to the processing condition information from the total power consumption (P _total ).

Next, in step S123, the calculating unit 120 may (b3) calculate the material removal rate ( MRR ) corresponding to the cutting power consumption (P _cutting ) calculated in step S22.

Next, in step S124, the calculation unit 120 bases (b4) data on the correlation between the wear level of the cutting tool according to the machining condition information stored in the previously constructed database 101 and the cutting power consumption (P _cutting ). You can calculate the wear rate of the cutting tool.

Next, in step S125, the calculating unit 120 may (b5) calculate the expected time it will take for the wear level of the cutting tool to reach a preset critical level based on the wear rate calculated in step S124.

Additionally, in step S125, the calculation unit 1250 may calculate the remaining life of the cutting tool based on the calculated expected time and machining time information (T _machining ).

In the above description, steps S121 to S125 may be further divided into additional steps or combined into fewer steps, depending on the implementation of the present application. Additionally, some steps may be omitted or the order between steps may be changed as needed.

Figure 8 is a detailed operation flowchart of a process for adaptively controlling the machining conditions of a cutting tool.

The process of adaptively controlling the processing conditions of the cutting tool shown in FIG. 8 may be performed by the control device 100 described above. Therefore, even if the content is omitted below, the content described with respect to the control device 100 can be equally applied to the description of FIG. 8.

Referring to FIG. 8, if the user requests active control to shorten the processing time, the active control unit 130 may increase the feed speed ( Feed ) in a range below a preset upper limit value in step S1311. Additionally, the machining time performed by the cutting tool in step S1312 may be shortened according to the active control performed in step S1311.

Conversely, if the user requests active control to increase the remaining life of the cutting tool, in step S1321, the active control unit 130 performs active control to lower at least one of the rotation speed ( N ) and the feed speed ( Feed ). You can. Additionally, the remaining life of the cutting tool may increase in step S1322 (in other words, the predicted value for the remaining life of the cutting tool may increase) according to the active control performed in step S1321.

In the above description, steps S1311 to S1322 may be further divided into additional steps or combined into fewer steps, depending on the implementation of the present application. Additionally, some steps may be omitted or the order between steps may be changed as needed.

The method for predicting the life of a cutting tool and actively controlling cutting conditions according to an embodiment of the present application may be implemented in the form of program instructions that can be executed through various computer means and recorded on a computer-readable medium. The computer-readable medium may include program instructions, data files, data structures, etc., singly or in combination. Program instructions recorded on the medium may be specially designed and constructed for the present invention or may be known and usable by those skilled in the art of computer software. Examples of computer-readable recording media include magnetic media such as hard disks, floppy disks, and magnetic tapes, optical media such as CD-ROMs and DVDs, and magnetic media such as floptical disks. -Includes optical media (magneto-optical media) and hardware devices specifically configured to store and execute program instructions, such as ROM, RAM, flash memory, etc. Examples of program instructions include machine language code, such as that produced by a compiler, as well as high-level language code that can be executed by a computer using an interpreter, etc. The hardware devices described above may be configured to operate as one or more software modules to perform the operations of the present invention, and vice versa.

Additionally, the above-described method of predicting the life of a cutting tool and actively controlling cutting conditions may be implemented in the form of a computer program or application executed by a computer stored in a recording medium.

The description of the present application described above is for illustrative purposes, and those skilled in the art will understand that the present application can be easily modified into other specific forms without changing its technical idea or essential features. Therefore, the embodiments described above should be understood in all respects as illustrative and not restrictive. For example, each component described as single may be implemented in a distributed manner, and similarly, components described as distributed may also be implemented in a combined form.

The scope of the present application is indicated by the claims described below rather than the detailed description above, and all changes or modified forms derived from the meaning and scope of the claims and their equivalent concepts should be construed as being included in the scope of the present application.

100: Cutting tool life prediction and cutting condition active control device
110: Collection department
120: calculation unit
130: Active control unit
140: Notification generation unit
101: Database

Claims (16)

In the method of predicting the life of a cutting tool and actively controlling cutting conditions,
(a) acquiring total power consumption by cutting processing, processing condition information and processing time information of a cutting tool performing the cutting processing;
(b) calculating the wear level and remaining life of the cutting tool based on the total power consumption, the processing condition information, and the processing time information; and
(c) adaptively controlling machining conditions of the cutting tool based on the calculated wear level and remaining life,
Including,
In step (b),
(b1) calculating a cutting length based on the processing condition information and the processing time information;
(b2) calculating cutting power consumption by subtracting machine power consumption calculated according to the processing condition information from the total power consumption;
(b3) calculating a material removal rate corresponding to the cutting power consumption;
(b4) calculating the wear rate of the cutting tool based on the processing condition information stored in a previously established database and the wear level of the cutting tool according to the cutting power consumption; and
(b5) calculating the expected time it will take for the wear level to reach a preset critical level based on the wear rate, and calculating the remaining life based on the expected time and the processing time information,
A control method comprising: According to paragraph 1,
In step (c),
A control method, wherein the processing conditions are changed to increase the remaining life or the processing conditions are changed to shorten the processing time using the cutting tool. According to paragraph 2,
The processing conditions include the rotation speed and feed speed of the cutting tool,
In step (c),
(c1) increasing the feed rate so that the processing time is shortened,
A control method comprising: According to paragraph 2,
The processing conditions include the rotation speed and feed speed of the cutting tool,
In step (c),
(c2) lowering at least one of the rotational speed and the conveying speed to increase the remaining life,
A control method comprising: According to paragraph 1,
(d) generating a request for replacement of the cutting tool when the remaining life is below a preset threshold or when the wear level exceeds a preset wear level;
A control method further comprising: delete According to paragraph 3,
In step (b),
When a change in the processing condition information is detected, the control method is re-performed by reflecting the changed processing condition information. In clause 7,
When a change in at least one of the rotation speed and the feed speed is detected,
In step (b),
A control method, wherein the expected time is recalculated by reflecting the changed processing condition information, and the remaining life is updated by subtracting the processing time information up to before the change was detected from the recalculated expected time. According to clause 8,
When a change in at least one of the cutting width and cutting depth among the processing condition information is detected,
In step (b),
Recalculating the material removal rate by reflecting the changed processing condition information and recalculating cutting power consumption according to the recalculated material removal rate;
A control method comprising: According to clause 9,
A control method wherein the change in at least one of the cutting width and cutting depth is detected based on the difference between a previously calculated material removal rate corresponding to the cutting power consumption and a material removal rate recalculated according to the change in the cutting power consumption. . According to clause 9,
A control method, characterized in that a change in at least one of the cutting width and cutting depth is detected when the cutting processing corresponding to complex shape processing is performed. In the device for predicting the life of a cutting tool and actively controlling cutting conditions,
A collection unit that acquires total power consumption by cutting processing, processing condition information and processing time information of a cutting tool performing the cutting processing;
a calculation unit that calculates a wear level and remaining lifespan of the cutting tool based on the total power consumption, the processing condition information, and the processing time information; and
An active control unit that adaptively controls machining conditions of the cutting tool based on the calculated wear level and remaining life,
Including,
The calculation unit is,
Calculate the cutting length based on the processing condition information and the processing time information, calculate the cutting power consumption by subtracting the machine power consumption calculated according to the processing condition information from the total power consumption, and correspond to the cutting power consumption. Calculate the material removal rate, calculate the wear rate of the cutting tool based on the processing condition information stored in the existing database and the wear level of the cutting tool according to the cutting power consumption, and calculate the wear rate of the cutting tool based on the wear rate. A control device that calculates an expected time required for the wear level to reach a preset critical level and calculates the remaining life based on the expected time and the processing time information. According to clause 12,
The active control unit,
A control device that changes the processing conditions so that the remaining life increases or changes the processing conditions so that the processing time using the cutting tool is shortened. According to clause 13,
The processing conditions include the rotation speed and feed speed of the cutting tool,
The active control unit,
A control device that increases the feed rate to shorten the processing time or lowers at least one of the rotation speed and the feed rate to increase the remaining life. According to clause 12,
A notification generator that generates a request for replacement of the cutting tool when the remaining life is less than a preset threshold or the wear level exceeds a preset wear level;
A control device further comprising: delete

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